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Front page OPERATING INSTRUCTIONS FLOWSIC100 Flare Description Installation Operation Document Information Product Product name: FLOWSIC100 Flare Document ID Title: Part No.: Version: Release: Operating Instructions FLOWSIC100 Flare 8013344 2.2 2014-05 Manufacturer SICK AG Erwin-Sick-Str. 1 Phone: Fax: E-mail: · D-79183 Waldkirch · Germany +49 7641 469-0 +49 7641 469-1149 [email protected] Place of Manufacture SICK Engineering GmbH Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany Trademarks Windows is a Microsoft Corporation trademark. Other product names used in this document may also be trademarks and are only used for identification purposes. Original documents The English edition 8013344 of this document is an original document from the manufacturer. SICK AG assumes no liability for the correctness of an unauthorized translation. Please contact the publisher in case of doubt. Legal information Subject to change without notice. © SICK AG. All rights reserved. 2 FLOWSIC100 Flare Operating Instructions 8013344 V 2.2 © SICK AG Warning Symbols Hazard (general) Voltage Hazard Explosive or combustible gas hazard Noxious substance hazard Warning levels / Signal words DANGER Risk or hazardous situation which will result in severe personal injury or death. WARNING Risk or hazardous situation which could result in severe personal injury or death. CAUTION Hazard or unsafe practice which could result in personal injury or property damage. NOTICE Hazard which could result in material damage. Information Symbols Information about use in potentially explosive atmospheres. Important technical information for this product Supplementary information Link to information in another place FLOWSIC100 Flare Operating Instructions 8013344/2014-05 (V 2.2) © SICK AG 3 Contents 4 Contents 1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.2 1.2.1 1.2.2 1.2.3 1.2.4 Main hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hazards due to hot, cold (cryogenic) or aggressive gases, or high pressure . . . . . 11 Hazards with electrical equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hazards due to explosive or combustible gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hazards due to electrostatic discharges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.3 1.3.1 1.3.2 1.3.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Restrictions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.4 1.4.1 1.4.2 Responsibility of user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Safety information and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.5 Transport safety device for retractable sender/receiver units . . . . . . . . . . . . . . . . . . . . 21 2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.1 2.1.1 2.1.2 2.1.3 2.1.4 System basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 System configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Communication between sender/receiver units and control unit . . . . . . . . . . . . . . 28 System overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FLSE100 sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Mounting accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Nozzle installation tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 MCUP control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Connection cables and cable glands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Meter body option (spoolpiece) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 2.3 2.3.1 2.3.2 2.3.3 2.3.4 Computations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Calculation and calibration of volume flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Mass flow and molecular weight determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Necessity for using external pressure and temperature transmitters . . . . . . . . . . . 70 Response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 2.4 2.4.1 2.4.2 2.4.3 Check cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Zero point control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Span test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Analog output of check cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Contents 3 Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 3.1 3.1.1 3.1.2 3.1.3 Project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Determining the measuring and installation location . . . . . . . . . . . . . . . . . . . . . . . . . 77 Further notes for project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Notes for installation of sender/receiver units in 1-path, 2-paths or 3x1 path configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 3.2 3.2.1 3.2.2 Preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Special notes for handling the meter body option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 3.3 3.3.1 3.3.2 3.3.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Fitting the nozzles on the pipeline (measuring systems without meter body) . . . . 86 Installing the meter body (option) in the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Installing the MCUP control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 3.4 Installing the MCUP with option "Set fixing plate for 2-inch post" . . . . . . . . . . . . . . . .104 3.5 3.5.1 3.5.2 Installing the sun roof MCUP (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Sun roof MCUP for wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Sun roof MCUP mounting on 2-inch post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 3.6 3.6.1 3.6.2 General notes for installation of sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . .111 Installing non-retractable sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Installing retractable sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.7.6 3.7.7 3.7.8 3.7.9 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 General information, prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Cable requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Requirements for installation in the Ex zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Connection of sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 MCUP connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Fitting and connecting the Interface and I/O module options . . . . . . . . . . . . . . . . . 138 Connection of external pressure and temperature transmitters . . . . . . . . . . . . . . . 145 Connection of relay contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 5 Contents 4 Start-up and Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 4.1 4.1.1 4.1.2 4.1.3 4.1.4 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Installing the operating and parameter program SOPAS ET . . . . . . . . . . . . . . . . . . 149 Connecting to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Information on using the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 4.2 4.2.1 4.2.2 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10 4.2.11 Standard start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Entering application-specific parameters in the sender/receiver units . . . . . . . . 161 Entering application specific parameters for single-path configuration in the MCUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Configuration of application-specific parameters for 10“ pipelines and 2-path configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Determining the check cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Setting the analog outputs parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Setting parameters for the pulse output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Setting the analog inputs parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Defining the limit value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Logbook function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Starting normal measuring operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 Advanced start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Entering customer data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Entering counter function parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Data archives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Entering process parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Setting Interface module parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Setting Modbus and HART® bus module parameters. . . . . . . . . . . . . . . . . . . . . . . . 189 Calibrating gas velocity measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 4.4 4.4.1 4.4.2 4.4.3 4.4.4 Operating/setting parameters via the optional LC-Display . . . . . . . . . . . . . . . . . . . . . . 191 General information on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Parameter setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Using SOPAS ET to modify display settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 5 Maintenance 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 5.2 5.2.1 5.2.2 Maintaining the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Removing sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Cleaning the sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 5.3 Maintaining the MCUP for use zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 4.2.3 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Contents 6 Specifications 6.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 Dimensions and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 FLOWSIC100 EX-S sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 FLOWSIC100 EX/EX-RE sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 FLOWSIC100 EX-PR sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Sender/receiver units - parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Junction box for Ex zone 2 (for ATEX versions only) . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Additional accessories for retractable sender/receiver units . . . . . . . . . . . . . . . . . 225 MCUP control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 6.3 6.3.1 6.3.2 6.3.3 Options for MCUP control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 Inputs/outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Interface module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Interface modules for MCUP 19" version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 6.4 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 6.5 Sealing installation instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231 6.6 SICK Commissioning check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233 6.7 Connection diagrams for MCUP Ex zone 1 - configuration examples with optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 6.8 6.8.1 6.8.2 6.8.3 Wiring diagrams for USA and Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245 FLSE100-EXS/FLSE100-EXPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 FLSE100-EX/FLSE100-EXRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 Connection of external pressure and temperature transmitters . . . . . . . . . . . . . . . 256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 7 Contents 8 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Important Information FLOWSIC100 Flare 1 Important Information Subject to change without notice About this document Main hazards Intended use Responsibility of user Transport safety device for retractable sender/receiver units FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 9 Important Information 1. 1 About this document These Operating Instructions contain basic information on function, installation, start-up and maintenance. For detailed information on functional checks/device settings, data backup, software update, malfunction and error handling and possible repairs, see the Service Manual for the FLOWSIC100 Flare measuring system. Subject to change without notice NOTICE: Always read the Operating Instructions before starting any work! The observance of all safety and warning notes is imperative! 10 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Important Information 1.2 Main hazards 1.2.1 Hazards due to hot, cold (cryogenic) or aggressive gases, or high pressure The sender/receiver units are mounted directly on the gas-carrying pipeline. On equipment with low hazard potential (e.g. non-toxic, aggressive or explosive gases; gases not hazardous to health; uncritical pressure; moderate gas temperature (not hot or very low/cryogenic), the installation or removal can be performed while the equipment is in operation, however only as far as the valid regulations and equipment safety notices are observed and suitable protective measures are taken. Special regulations that apply to the plant must be observed. WARNING: Gas hazard Activities on equipment with increased hazard potential, e.g. by toxic, aggressive, explosive gases, health endangering, higher pressure, high temperatures, low temperature (cryogenic), have to follow legitimate regulations, general standards and guidelines as well as plant operator instructions. Only authorized personnel with special qualification for the "hot tapping" method may fit devices on running equipment (authorized personnel pg. 19, § 1.4). Otherwise, serious injuries might occur, e.g. poisoning, burns etc.. These persons must be trained and technically adept in "hot tapping" installation work and must know and implement legal as well as generally applicable regulations and in-house regulations. The express approval of the plant operator in written form is required for installations on running equipment at all times. The plant operator carries the responsibility for professional implementation alone. All safety requirements relevant for the equipment must be observed as well as essential and suitable protective measures taken. All regulations/special regulations that can be applicable for the plant must be observed. 1.2.2 Hazards with electrical equipment The FLOWSIC100 Flare measuring system is equipment used for operation of industrial high-voltage plants. WARNING: Mains voltage Danger Disconnect mains lines before working on mains connections or parts carrying mains voltage. Refit any contact protection removed before switching the mains voltage on again. Subject to change without notice 1.2.3 Hazards due to explosive or combustible gases The FLOWSIC100 Flare measuring system may be used in potentially explosive atmospheres according to the respective specifications. WARNING: Hazards due to explosive or combustible gases In potentially explosive atmospheres, only use the version of the FLOWSIC100 Flare specified for such use ( pg. 13, § 1.3.2). Observe the information on pg. 11, § 1.2.1 during installation work on running equipment ("hot tapping" method). FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 11 Important Information 1.2.4 Hazards due to electrostatic discharges The electronic housing of the FLSE100 and of the optionally available meter body is painted by the manufacturer with a layer thickness of max. 0.2 mm. Subject to change without notice WARNING: Ignition hazards through electrostatic discharges exist when the FLOWSIC100 Flare with special paint and a layer thickness > 0.2 mm is used in applications with ignition group IIC in accordance with ATEX and IECEx. For installation, the risk of electrostatic charging of the surface must be reduced to a minimum. Use appropriate caution when performing maintenance and cleaning work. For example, the surfaces should only be cleaned with a damp cloth. The affected devices will be identified by the manufacturer by a warning label. 12 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Important Information 1.3 Intended use 1.3.1 Purpose of the device The FLOWSIC100 Flare measuring system may only be used for measurements of gas velocity, gas volume, mass flows and molecular weight in pipelines. 1.3.2 Correct use 1.3.2.1 General Use the device only as described in these Operating Instructions. The manufacturer bears no responsibility for any other use. Observe all measures necessary for conservation of value, e.g. for maintenance and inspection and/or transport and storage. Do not remove, add to or modify any components on the device unless described and specified in the official manufacturer information. Otherwise – the device could become dangerous – any warranty by the manufacturer becomes void Do not use damaged components or parts. 1.3.2.2 FLSE100 sender/receiver units for use in ex zones The sender/receiver units of the FLOWSIC100 EX-S, EX, EX-RE and EX-PR device versions are available as options for use in Ex zone 1 and 2 or as versions for use in Ex zone 2 only. ● Sender/receiver units marked ATEX II 2 G IECEx and CSA Class I Division 1 are approved for use for gases in Ex zones 1 and 2. ● Sender/receiver units marked ATEX II 3 G and CSA Class I Division 2 are suitable for use for gases in Ex zone 2. 1.3.2.3 Use of FLOWSIC100 FLARE depending on temperature class and process temperature Subject to change without notice Installation and use of sender/receiver units FLSE100 where electronic parts and transducer parts are in the same area This area is a hazardous area, i.e. zone 1 or zone 2 in which an explosive atmosphere exists under normal atmospheric conditions of: – specified ambient temperature -40 ... +70 °C for T4 or -40 ... +55 °C for T6, optionally minimum ambient temperature -50 °C – ambient pressure 80 kPa (0.8 bar) to 110 kPa (1.1 bar) – air with normal oxygen content, typically 21 % v/v. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 13 Important Information 1.3.2.4 Permitted gas temperature depending on temperature code of FLSE100 Case 1 (see p. 14, Table 1): Outside the pipeline an explosive atmosphere exists under normal atmospheric conditions, which is categorized as area zone 1 or zone 2. Inside the pipeline the process conditions can be different from atmospheric conditions. Process conditions can be in the range as specified on the tag of the FLSE100. In this case the gas or gas mixture can be combustible but must not be explosive. Case 2 and 3 (see p. 14, Table 1: On both sides of the pipeline an explosive atmosphere exists under normal atmospheric conditions. The pipe wall separates different zones, i.e. inside the pipe is zone 1 and outside the pipe is zone 2. This means the gas temperature and the line pressure must not exceed the specified ambient values. NOTICE: The pipe wall can separate different hazardous areas (zones). Table 1 Permitted gas temperature for temperature code Case 1 ● Ultrasonic transducer outside explosive atmosphere Requested Zone 1 or 2 temp. class for ● Electronics in explosive hazardous atmosphere Zone 1 or 2 area ● Gas pressure and gas temperature according to specification on device label Zone 1 or 2 Non-ex atmosphere Case 2 ● Ultrasonic transducer in explosive atmosphere Zone 1 or 2 ● Electronics in explosive atmosphere Zone 1 or 2 ● Gas pressure and gas temperature according to ambient specification of device Zone 1 or 2 Zone 1 or 2 Case 3 ● Ultrasonic transducer in explosive atmosphere zone 0 ● Electronics in explosive atmosphere Zone 1 or 2 ● Gas pressure atmospheric, gas temperature max +60 °C ● For type EX-S and EX-PR only Zone 1 or 2 Zone 0 The standard FLSE100 (Temperature Code T4) can be used in the following gas temperatures: T4 -70 … +130 °C1 -40 … +70 °C2 -20 … +60 °C 1 3 2 T3 -70 … +195 °C -40 … +70 °C -20 … +60 °C T2 -70 … +280 °C1 3 -40 … +70 °C2 -20 … +60 °C FLSE100 with Option T6 (not available for versions with high temperature range): T6 -70 … +80 °C1 -40 … +55 °C2 -20 … +55 °C 1 Option low temperature version with minimum temperature -196 °C (not available for EX/EX-RE Zone 1 and CSA) Option minimum temperature -50 °C 3 Limit for FLSE100 Standard temperature +180 °C, limit for FLSE low temperature version +100 °C Subject to change without notice 2 14 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Important Information NOTICE: If the real gas temperature in the pipeline is higher than the ignition temperature marked by the temperature code on the tag of the FLSE100, the possible explosive atmosphere does not contain gases which are classified in a temperature code with a lower ignition temperature than the highest gas temperature respectively the outside surface temperature of the pipeline itself. The possibility for heating up of the ambient air by the pipeline around that must be observed. Ambient temperature around the electronic enclosure must not exceed +70 °C for FLSE100 marked with T4 and must not exceed +55 °C for FLSE100 marked with T6. The compliance with these requirements is the sole responsibility of the user. Particularly the FLSE100 marked with temperature code T6 run the risk of non-resettable switch-off due to the thermal cutoffs inside the electronics enclosure. In this case the FLSE100 must be repaired by the manufacturer only. Warranty will be expired. Subject to change without notice Compliance with the above requirements is the sole responsibility of the user. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 15 Important Information 1.3.2.5 Sender/receiver unit with probe retraction mechanism The retraction mechanism serves to remove and fit complete FLOWSIC100 Flare sender/ receiver units for maintenance or replacement without relieving pressure in the pipeline in which the measuring system is fitted. This allows maintenance work without having to interrupt the process. WARNING: Specified temperature and pressure ranges Only operate probe retraction mechanism in the following ranges for gas temperature and operating pressure: ● Device types FL100 EX-S, EX and EX-RE: – Gas temperature range -20°C to +200 °C – Upper operating pressure 16 bar at 50 °C (see p-T diagrams in chapter 2.3.1.1 - 2.3.1.6.) ● Device type FL100 EX-PR – Gas temperature range -20°C to +200 °C – Upper operating pressure limit is +0.5 bar at whole temperature range. WARNING: Hazardous gas (possibly explosive or toxic) Small gas quantities escape during the removal and installation of the transducer assemblies. During proper use, the gas crowd locked up in the retraction space is less than 0.5 dm³ for device type EX-S, EX and EX-RE and less than 2.5 dm³ for device type EX-PR. Staff performing activities at plants with poisonous or other gases dangerous to health must use suitable safety equipment to prevent personal injuries. WARNING: Hazardous gas (possibly explosive or toxic) The retraction flange of the S/R units contains a connection for optional venting ( Fig. 8, Fig. 12 and Fig. 16 - Fig. 22). This connection is closed with a blind screw by factory and may not be removed outside factory! 1.3.2.6 MCUP control unit The MCUP control unit is optionally available in the versions for use in Ex zone 1 and 2 or for use only in Ex zone 2 or not for use in Ex zones. WARNING: Explosion hazard Install and operate the MCUP control unit without explosion protection only outside Ex zones. Use the explosion-protected MCUP control unit only according to the respective Ex marking. 16 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice ● Control units with marking ATEX II 2 G Ex de II C T6 are approved for use in Ex zone 1 and 2. ● Control units with marking ATEX II 3 G Ex nA IIC T4 Gc are approved for use only in Ex zone 2 or for use in safe areas. Important Information 1.3.3 Restrictions of use WARNING: Pressure/temperature hazard Use the measuring system only within the pressure and temperature limits specified in these Operating Instructions and on the device type plate. The selected materials must be resistant to the process gases. WARNING: Dangerous voltage ● With the use of sender/receiver units FLSE100-EXS and EXPR zone 1 the rated voltage UM used in the safe area may not exceed 125 V. Higher voltages can jeopardize intrinsic safety of the ultrasonic transducer circuit when errors occur. Ensure that the rated voltage UM used in the safe area does not exceed 125 V. ● The FLOWSIC100 Flare is not equipped with a power switch. Plan and install a suitable switching off device. Subject to change without notice The ultrasonic transducers/probes are preferably intended for installation in gas-carrying pipelines. It is not absolutely necessary that atmospheric conditions prevail within the pipeline. The pipe wall is then a zone-separating wall, i.e. no Ex zone is defined within the pipeline, at least temporarily. WARNING: Leakage hazard Operation with leakage is not permitted. ● The metallic and hermetically sealed, fully welded housing and the seal must comply with all safety requirements which must also be fulfilled by the pipeline itself with respect to design pressure and temperature and compatibility of the material with the medium. ● The ultrasonic transducers with their gas-tight and pressure-proof housings must be installed in the pipeline gas-tight and pressure-tight. Depending on the design, at least one seal with an O-ring according to DIN 3771 or a standardized sealing flange must be provided. ● The sealing itself must consist of material which is compatible with the medium and is suitable for the application conditions. Check the sealing surfaces and elements for intactness before installation. Check the sealing effect with suitable methods after installation. Regularly check leak-tightness during operation and replace the seal, as required. ● The sealing effect must be checked with suitable methods after installation and every removing and re-installation. Leak-tightness is to be checked regularly during operation and the seal replaced, as required. Before every reinstallation new seals have to be used in the required design. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 17 Important Information Use of the FLSE100-EXS and FLSE100-EXPR sender/receiver units in zone 1 and zone 0 Application limitations for use in hazardous area classification Ex zone 1 After the transitional period of Directive EN 60079-0:2009 has elapsed, the following additional regulations are immediately applicable for the use of FLOWSIC100 Flare in applications with Ex zone 1: Ultrasonic probes made of titanium may be used in zone 1 only when risks of ignition arising from impacts or friction on the sensor housing can be ruled out. When ultrasonic probes are installed in pipelines with a defined hazardous area, solid parts, e.g. dust or other particles may not cause an ignition hazard. Application limitations for use in hazardous area classification Ex zone 0 in the pipeline The use in applications of zone 0 is generally possible only for device types FLOWSIC100 EX-S and EX-PR under consideration of the application limitations specified in these Operating Instructions. Subject to change without notice ● Ultrasonic probes can also be operated in zone 0 under atmospheric conditions (ambient temperature -20°C to 60°C and ambient pressure 0.8 bar to 1.1 bar absolute). The device must be labelled at least with the information II 1/2 G Ex ia. ● Ultrasonic probes made from titanium may be used in zone 0 only if the medium does not contain firm parts (e.g. dust and other particles), and the ultrasonic probes are installed in the zone 0 (e.g. the inside of a pipe) in such a way that the danger of ignition due to impact or friction is excluded. The intrinsically safe ultrasonic transducers with their gas-tight and pressure-proof housings must be installed gas-tight and pressure-tight in the wall separating the zones to zone 0. The wall must be thicker than 3 mm. The requirements in EN 60079-26 section 4.6 must be adhered to. 18 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Important Information 1.4 Responsibility of user 1.4.1 General information Designated users The FLOWSIC100 Flare measuring system may only be installed and operated by skilled technicians who, based on their technical training and knowledge as well as knowledge of the relevant regulations, can assess the tasks given and recognize the hazards involved. Technicians must be skilled according to DIN VDE 0105 or IEC 364 or directly comparable standards. The named persons must have exact knowledge of operational hazards caused e.g. by hot, toxic, explosive gases or gases under pressure, gas-liquid mixtures or other media as well as adequate knowledge of the measuring system gained through training. Specific requirements for use of devices in hazardous areas Cabling /installation, device set-up, maintenance and check may be only carried out by experienced staff which has knowledge about the rules and regulations for hazardous areas, in particular: – type of protection – installation rules – area definition Regulations to be applied: – IEC 60079-14 – IEC 60079-17 or comparable national regulations. Special local conditions Observe the valid legal regulations as well as the technical rules deriving from implementation of these regulations applicable for the respective equipment during work preparation and performance. Special caution and attention is required on equipment with increased hazard potential (pressure pipes, explosion protection zones). Comply with existing special regulations. Carry out work according to the local conditions specific for the equipment as well as operational hazards and regulations. Suitable protection devices and safety equipment for persons must be available according to the respective hazard potential and be used by the personnel. Subject to change without notice Retention of documents Keep the Operating Instructions belonging to the measuring system as well as equipment documentation on-site for reference at all times. Pass the respective documentation on to any new owner of the measuring system. Selection of materials The user must check whether the intended materials of the device components are suitable for the process conditions. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 19 Important Information 1.4.2 Safety information and protective measures Protection devices NOTICE: Suitable protection devices and safety equipment for must be available according to the respective hazard potential for use by personnel. Preventive measures for operating safety NOTICE: The user must ensure that: Neither failures nor erroneous measurements lead to operational states that can cause damage or become dangerous The specified maintenance and inspection tasks are carried out regularly by qualified, experienced personnel. Recognizing malfunctions Every deviation from normal operation is to be regarded as a serious indication of a functional impairment. These are, amongst others: ● Warning displays (e.g. heavy contamination) ● Large drifts in measured results ● Increased power input ● Higher temperatures of system parts ● Monitoring device triggering ● Smells or smoke emission Avoiding damage NOTICE: The operator must ensure the following to avoid malfunctions that can directly or indirectly lead to injuries to persons or material damage: The responsible maintenance personnel are present at any time and as quickly as possible The maintenance personnel are adequately qualified to react correctly to malfunctions of the measuring system and any resulting operational malfunctions (e.g. when used for measurement and control purposes) The malfunctioning equipment is switched off immediately in case of doubt and that switching off does not cause collateral malfunctions. NOTICE: Repairs on explosion-protected system components are possible only by the device manufacturer and, to a limited extent, also by others. For detailed information about possible repairs and repair instructions see the service manual. 20 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Repairs Important Information 1.5 Transport safety device for retractable sender/receiver units To prevent transport damage, retractable sender/receiver units must be secured before each transport according to Fig. 1: The transducer must be on the retraction flange. The probe tube with transducer must be secured with cotter pins. Fig. 1 Transport safety device for retractable sender/receiver unit (shown semitransparent) Retraction flange Probe tube Transducer Subject to change without notice Cotter pin FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 21 Subject to change without notice Important Information 22 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description FLOWSIC100 Flare 2 Product Description Subject to change without notice System basic information System components Computations Check cycle FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 23 Product Description 2. 1 System basic information 2.1.1 Functional principle The FLOWSIC100 Flare gas velocity measuring devices operate according to the principle of difference measurement in ultrasonic transit times. On both sides of a pipeline, the sender/receiver units are installed in a certain path angle to the gas flow ( Fig. 2). The sender/receiver units contain piezoelectric ultrasonic transducers which operate alternately as senders and receivers. The sonic pulses are beamed at angle to the gas flow direction. Depending on angle and gas velocity v, different transit times for the respective sound direction (formulas 2.1 and 2.2) result from "acceleration or brake effects". The higher the gas velocity and the smaller the angle to the flow direction, the more the transit times of the sound pulses differ. Gas velocity v is determined from the difference of both transit times, irrespective of the value of the sound velocity. With this measuring method, changes of the sound velocity due to pressure or temperature variations therefore have no influence on the gas velocity determined. Fig. 2 Functional principle of FLOWSIC100 Flare Sender/ receiver unit, master (probe A) v tAB tBA POWER Meas v = gas velocity in m/s L = active measuring path in m = path angle in ° tAB = transit time of the sound in flow direction tBA = transit time of the sound against the flow Subject to change without notice Sender/ receiver unit, slave (probe B) L 24 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description Determination of gas velocity Measuring path L is equivalent to the active measuring path, i.e. the free flow path. For measuring path L, sound velocity c and path angle between sound and flow directions, the following is valid for the transit time of the sound for sound propagation in direction of the gas flow (forward direction): tAB = L c + v · cos (2.1) Valid against the flow is: L c - v · cos tBA = (2.2) Resolving for v results in: v= L 2 · cos · (t1AB ) 1 tBA (2.3) i.e. a relation in which, except for the two transit times measured, only the active measuring path and the path angle exist as constants. Determination of sound velocity The sound velocity can be determined by resolving formulas 2.1 and 2.2 for c. c= ( L tAB + tBA · 2 tAB · tBA ) (2.4) Based on the dependencies according to formula 2.5, the sound velocity can be used for the determination of the gas temperature, of the molecular weight and for diagnostic purposes. c = c0 · 1+ 273°C (2.5) Subject to change without notice Volume flow determination The volume flow in operating mode is calculated from the gas velocity and the geometric dimensions of the pipeline. pg. 70, § 2.3.2 describes the calculations for volume flow in standard state, mass flow and molecular weight. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 25 Product Description 2.1.2 System configuration The following figures show cross-duct installations (FLOWSIC100 EX/ EX-RE, EX-S). In principle, the configuration is also valid for single side installations (FLOWSIC100 EX-PR). Configuration Description 1-path measurement 2 sender/receiver units (1) are mounted on the pipeline (2). The measurement path (3) is positioned across the center of the pipeline. Special application conditions can require a path positioning outside the center of the pipeline (shortening of active measuring path). Instead of 2 sender/receiver units also a probe version can be used (type EX-PR). 1 1 2 3 2x1-path measurement In this configuration the control unit MCUP serves two independent 1-path measurement systems. Both pairs of sender/receiver units are connected to the same control unit MCUP. Separate processing and output of the measuring results for both measuring points is performed by the MCUP. Preferably both measurements are installed like standard 1-path measurements in the center of the pipeline. 2-path measurement Two pairs of sender/receiver units are installed at the same measuring location and are connected to the same control unit MCUP. Both measurement paths should preferably be positioned outside the center of the pipeline and run parallel to one another. Computation of both measuring paths to one measuring result is performed via the MCUP. Subject to change without notice Two-path measurement is used to achieve higher measuring precision or for complicated flow conditions. Path compensation The device is uses an integrated algorithm for path compensation in the case of a path failure. In trouble-free function, the system learns the relation of gas velocity and sound velocity between both measurement paths. In case of a path failure, the system can calculate theoretical values on basis of the learned path relations and can replace the invalid values against them. In this way the path failure can be temporarily compensated and the measurement is continued with slightly increased uncertainty. Under such conditions, the measurement system automatically signals "Maintenance request". 26 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description Description 3x1-path measurement Three individual measuring paths from different measuring points can be connected to one control unit with this variant. Separate processing and output of the measuring results for all three measuring points are performed by the MCUP. Subject to change without notice Configuration FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 27 Product Description 2.1.3 Communication between sender/receiver units and control unit Configuration Description 1-path measurement connection of one measuring point to the MCUP Two sender/receiver units (type EX-S, EX und EX-RE) are connected to the MCUP and work as master and slave. The FLSE master has a second interface in the terminal box to enable unique separation of the communication to the FLSE slave and to the MCUP. The master triggers the slave and takes over the measuring regime. The MCUP can independently query the measured values from the master units (asynchronous to the measuring cycle). FLSE100 Master FLSE100 Slave The master-slave communication of the device type EX-PR is realized internally in the single sender/receiver unit. The sender/receiver unit is directly connected to the MCUP. 2-path and 2x1-path measurement connection and computation of two measuring paths of a measuring point to the MCUP The master-slave communication is realized using the same principle as for the single path measurement. The connection of both measuring paths is usually carried out with bus cabling. Junction box An approved explosion-protected junction box (SICK option) is to be used for cabling in Ex zone 2. Cabling in hazardous areas Ex zone 1 may be carried out only with an approved "Exe" junction box or "Ex-d" junction box (not included in SICK scope of delivery). 3x1-path measurement connection of three measuring paths of different measuring points to the MCUP The master-slave communication is realized using the same principle as for the single path measurement. The connection of all measuring paths have to be carried out with bus cabling. An approved explosion-protected junction box (SICK option) is to be used for cabling in Ex zone 2. Cabling in hazardous areas Ex zone 1 may be carried out only with an approved "Exe" junction box or "Ex-d" junction box (not included in SICK scope of delivery). FLSE100 Master FLSE100 Slave FLSE100 Master FLSE100 Slave FLSE100 Master FLSE100 Slave Subject to change without notice Junction box 28 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2.1.4 System overview Subject to change without notice The measuring system consists of the following components: ● FLSE100 sender/receiver unit (details pg. 31, § 2.2.1) For sending and receiving ultrasonic pulses, for signal processing and control of system functions ● Nozzle (details pg. 55, § 2.2.2.1) For mounting the sender/receiver units on the pipeline ● Nozzle installation tool For precise positioning and alignment of nozzles ● Ball valve (details pg. 57, § 2.2.2.2) For mounting retractable sender/receiver units on the pipeline ● MCUP control unit (details pg. 59, § 2.2.4) For control, evaluation and output of the sensor data connected via the RS485 interface ● Connection cable between the sender/receiver units ● Connection cable between sender/receiver units and MCUP ● Meter body option (spool piece) Spool piece ready for mounting in an existing pipeline (flange connection or welded connection); including installation materials to fit the sender/receiver units. ● External temperature and pressure transmitters available on request Device type Component FLOWSIC100 EX-S FLOWSIC100 EX FLOWSIC100 EX-RE FLOWSIC100 EX-PR FLSE100-EXS (master) FLSE100-EX (master) FLSE100-EXRE (master) FLSE100-EXPR Sender/receiver unit FLSE100-EXS (slave) FLSE100-EX (slave) FLSE100-EXRE (slave) non-retractable ANSI CL150 2" or DN50 PN16 nozzle ANSI CL150 3" or DN80 PN16 nozzle FLSE100 Installation retractable Nozzle, ball valve, blind flange ANSI CL150 2"/CL150 3"or DN50 PN16/DN80 PN16 material FLSE100 without explosion MCUP 90-250 V a.c. or 24 V d.c. protection ● MCUP Zone 1 (90 ... 250 V a.c. or 24 V d.c.) ● MCUP Zone 2 (24 V d.c., 115/230 V a.c.automatically FLSE100 certified for Ex zone 1: controlled) explosionMCUP Zone 2 (24 V d.c. or 115/230 V a.c. automatically MCUP protected FLSE100 with suitability for Ex zone 2: controlled ) Connection cable FLSE100 Scope of delivery Not relevant (master )-FLSE100 (slave) Measuring systems with meter body option can be provided additionally as: ● 3D measured Geometric uncertainties are minimized. ● Flow-calibrated Both variants increase the measuring accuracy ( pg. 202, § 6.1). FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 29 Product Description System overview of cross-duct version (example: FLOWSIC100 EX-S) Fig. 3 System overview, horizontal installation, FLOWSIC100 EX-S, MCUP without explosion protection Sender/receiver unit FLSE100-EXS Master Pressure sensor Connection cable Temperature sensor 3D O WE P R A L F U I R E A N M I T NA E NC E E U R QE T S D MCUP control unit without explosion protection Connection cable Sender/receiver unit FLSE100-EXS Slave Potentially explosive atmosphere zone 1 or zone 2 Fig. 4 Safe area System overview, horizontal installation, FLOWSIC100 EX-S, MCUP explosion protected Sender/receiver unit FLSE100-EXS Master Connection cable Pressure sensor Temperature sensor 3D MCUP control unit certified for Ex zone 1 and Ex zone 2 Sender/receiver unit FLSE100-EXS Slave Connection cable Potentially explosive atmosphere zone 1 or zone 2 30 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice MCUP control unit certified only for Ex zone 2 Product Description 2.2 System components 2.2.1 FLSE100 sender/receiver unit The sender/receiver units consist of the electronic unit (slave probe of type FLOWSIC100 EX-S without electronic unit), connecting piece and duct probe with transducer module. The individual modules of the sender/receiver unit are firmly interconnected at the factory to comply with the ex protection and thus form a unit which cannot be disassembled. Fig. 5 Schematic diagram of the modules of the sender/receiver unit Cross-duct version 1 2 3 4 9 5 10 6 7 8 Nominal length (NL) Probe version 1 2 3 4 5 10 11 NL Exe terminal compartment Electronic unit Connection Pressure balance element (not removable) Connection flange Duct probe 12 7 7 8 9 10 11 12 8 Transducer Flow-optimized probe contour Connection for slave probe (only for FLOWSIC100 EX-S) Ground terminal Fixing ring Supporting ring Subject to change without notice 1 2 3 4 5 6 6 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 31 Product Description Assignment device type - type of sender receiver unit Device type Name of sender/receiver unit FLOWSIC100 EX-S FLSE100-EXS FLOWSIC100 EX FLSE100-EX FLOWSIC100 EX-RE FLSE100-EXRE FLOWSIC100 EX-PR FLSE100-EXPR Sender/receiver unit versions ● Non-retractable sender/receiver units Cannot be installed or removed while the plant is in operation. ● Retractable sender/receiver units Can be installed or removed while the plant is in operation. Installation on the pipeline is performed with nozzle and ball valve ( pg. 112, § 3.6.2). Option: Venting ball valve for sender/receiver unit Retractable sender/receiver units can be delivered with optional "venting valve" equipment (ball valve) at the retraction flange. ● The venting ball valve must be installed by the manufacturer. Installation outside the factory is not possible. ● The connection for the venting valve is closed with a blind screw by the factory. WARNING: Danger of leakage Do not remove the blind screw at the connection for the venting valve! Option: Connection for condensation drain at sender/receiver unit Optional connection for condensation drain can be used under consideration of following restrictions only: ● Drain only over closed drain system. Drain system (piping etc.) is not included as part of delivery SICK. ● Drain system must be designed considering the process conditions (pressure, temperature, gas composition). All relevant safety regulations, standards and guidelines must be considered when using the condensation drain. The use of the condensation drain is the sole responsibility of the plant operator. 32 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice WARNING: Danger in case of incorrect use Retractable sender/receiver units without optional venting may only be used for non-hazardous gases (not aggressive/toxic/explosive, low temperatures) or otherwise only when the plant operator takes suitable protective measures and safety precautions for safe venting. Venting is only permitted if the process ball valve of the system is closed tightly! Product Description Selection criteria Criteria Gas temperature / EX certification Gas composition Type of installation Pipe diameter Flange connection Design Standard version up to max. 180°C High-temperature version up to max. 280°C Standard version up to max. 180°C High-temperature version up to max. 260°C Material for duct probe with transducer: stainless steel or titanium Two-sided installation One-sided installation Installation with nozzle Installation with nozzle + ball valve 4" ... 24" 12" ... 24" 8" ... 72" 12" ... 72" 12" ... < 48" 18" ... < 48" 48" ... 72" prepared for mounting on counter flange 2" CL150 RF acc. to ASME B16.5 or counter flange DN50 PN16 form B1 acc. to EN 1092-1 prepared for mounting on counter flange 3" CL150 RF acc. to ASME B16.5 or counter flange DN80 PN16 form B1 acc. to EN 1092-1 Remark Device certified for gases according to ATEX/IECEx in zone 1 and 2 and CSA Class 1 Division 1/Division 2 Devices with suitability for gases in zone 2 only Selection according to corrosion resistance with respect to the measuring medium one sender/receiver unit on each of the opposite pipe walls single sender/receiver unit (probe version) non-retractable sender/receiver units retractable sender/receiver units FLOWSIC100 EX-S, one path FLOWSIC100 EX-S, two path FLOWSIC100 EX /EX-RE, one path FLOWSIC100 EX /EX-RE, two path FLOWSIC100 EX-PR, one path, short version FLOWSIC100 EX-PR, two path, short version FLOWSIC100 EX-PR, one path/two path, long version FLSE100-EXS, EX and EXRE FLSE100-EXPR Subject to change without notice All sender/receiver units can be used for internal pipe pressure up to max. 16 bar. If requested by the customer, the sender/receiver units are also available in other versions. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 33 Product Description Material for gas-affected parts (standard configuration) Component EXS Duct probe, transducer, connection flange Connection for optional venting, retraction flange Stainless steel 1.4571 Duct probe, connection flange, sensor contour, fixing ring Duct probe, transducer Titanium Transducer, transducer holder (inside sensor contour) FFKM, EPDM, Sealings in retraction mechanism (not for high x PTFE temperature versions) Sealings in retraction mechanism (high temperature x FFKM, PTFE versions only) PTFE Centering Sensor contour PTFE, conductive Supporting ring EX x x Type FLSE100 EXRE EXPR non-retract. retract. x x N/A x x x x x x x x N/A x x N/A x x N/A x x x x x Subject to change without notice Material 34 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2.2.1.1 Parameter Type code for sender/receiver units ATEX Zone 1, IECEX and Zone 2 The sender/receiver units are defined by a type code as follows: Code EXS EX EXRE FLSE100 identification NL ( pg. 31, Fig. 5) EXPR 148 176 198 220 226 330 350 380 400 530 Subject to change without notice S T Material of transducer A with probe tube F A2 D5 A3 Connection flange D8 1 Probe design 2 4 8 Transducer 1 V E K Sealing material in retraction mechanism P 1 2 3 4 5 6 Design/Description Type of sender/receiver unit Transducer with small dimensions Transducer with medium dimensions Transducer with medium dimensions, retractable version of sender/receiver unit Transducer with small dimensions, probe version 148 mm FLSE100-EXS, non-retractable1 176 mm FLSE100-EXS, non-retractable2 198 mm FLSE100-EX, non-retractable1 220 mm FLSE100-EXPR, non-retractable, short version3 226 mm FLSE100-EX, non-retractable2 330 mm FLSE100-EXS, retractable4 350 mm FLSE100-EXPR, non-retractable, long version3 380 mm FLSE100-EXRE, retractable4 400 mm FLSE100-EXPR, retractable, short version3 530 mm FLSE100-EXPR, retractable, long version3 Stainless steel 1.4571, 1.4404, 316L, 316 Ti not for FLSE100-EXPR Titanium Hastelloy Full titanium execution see footnote 1 see footnote 2 FLSE100-EXS/EX/EXRE 5 see footnote see footnote 6 FLSE100-EXPR High flow center path High flow outer path (secant) 42 kHz preferably FLSE100-EX and EXRE 80 kHz preferably FLSE100-EXS 135 kHz preferably FLSE100-EXS and EXPR FKM EPDM FFKM PTFE Flange connection prepared for mounting on counter flange 2" CL150 RF acc. to ASME B16.5 Flange connection prepared for mounting on counter flange DN50 PN16 form B1 acc. to EN 1092-1 Flange connection prepared for mounting on counter flange 3" CL150 RF acc. to ASME B16.5 or counter flange DN80 PN16 form B1 acc. to EN 1092-1 Flange connection prepared for mounting on counter flange 2" CL150 RF acc. to ASME B16.5 or counter flange DN50 PN16 form B1 acc. to EN 1092-1 Flange connection prepared for mounting on counter flange 3" CL150 RF acc. to ASME B16.5 Flange connection prepared for mounting on counter flange DN80 PN16 form B1 acc. to EN1092-1 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 35 Product Description Type code for sender/receiver units ATEX Zone 1, IECEX and Zone 2 (continued) Parameter Gas temperature Probe retraction mechanism Code S H L Z N R V N Subject to change without notice Material of retraction flange S N 4 8 Probe electronics 1 1 2 Explosion protection 4 A B C Ex group 6 N S Electronic housing D N A Housing material S N P M Housing cable entry T N Junction box Y Design/Description Type of sender/receiver unit Standard range -70 ... +180°C High temperature range -70 ... +280 °C only for ATEX Zone 1/IECEX and CSA versions use in zone 1 only for FLSE100-EXS Low temperature range -196 ... +100 °C and EXPR - Titanium version High temperature range -70 ... +260 °C only for ATEX zone 2 versions Non-retractable Retractable (welded retraction flange) Retractable with vent (welded retraction flange) Without retraction flange Stainless steel 1.4571, 1.4404, 316L, 316 Ti non-retractable FLSE100 Without electronics FLSE100-EXS (slave probe) 1-channel F42 FLSE100-EX and EXRE 2-channel F80 FLSE100-EXS 2-channel F135 FLSE100-EXS and EXPR ATEX/IECEx zone 1 (IECEx not for FLSE with junction box) ATEX zone 2 INMETRO Zone 1 IIA T4 IIB T4 IIC T4 IIC T6 not for gas temperature > 80°C No electronics only valid for FLSE100-EXS slave probe Standard housing not for sender/receiver units for use in zone 1 Ex-d housing No electronics FLSE100-EXS (slave probe) Aluminium Stainless steel not for ATEX zone 2 versions No electronics FLSE100-EXS (slave probe) Plug connection Metric cable gland NPT cable gland Without junction box With junction box not suitable for armored cables, not for IECEX 36 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description Type code for sender/receiver units ATEX Zone 1/IECEX and Zone 2 (continued) Parameter Code N 1 Material documentation 2 N 1 2 3 4 Miscellaneous 5 S Design/Description Type of sender/receiver unit None Test Certificate 3.1 and compatibility NACE MR 0175:2003 (wetted parts) Test Certificate 3.2 and compatibility NACE MR 0175:2003 (wetted parts) None Ambient temperature range -50 ... +70°C Tropicalized electronics Offshore painting Offshore (housing/outer parts SS, standard offshore painting) Offshore (housing/outer parts SS, standard offshore painting) and tropicalized electronic Special Type code for sender/receiver units with certification CSA Cl I, Div1/Div2 pg. 245, § 6.8. Application area, configurations Gas temperature [°C] Type of sender/ receiver unit standard range high temperature range FLSE100-EXS -70 ... +180 -70 ... +280°C -70 ... +260°C for zone 2 FLSE100-EXS retractable FLSE100-EX -70 ... +280°C -70 ... +260°C for zone 2 FLSE100-EXRE FLSE100-EXPR -70 ... +280°C -70 ... +260°C for zone 2 FLSE100-EXPR retractable 1): 2): 3): 4): Pressure [barg] 16 16 16 1) 0.5 2) Active measuring Pipe diameter path [mm] [mm] NL [mm] 105 ... 620 100 ... 600 (4" ... 24") 148 / 176 330 205 ... 1850 200 ... 1800 (8" ... 72") 150 (fixed) 300 ... 1800 (12" ... 72") 198 / 226 380 220 3) / 350 4) 400 3) / 530 4) in measuring operation when retraction mechanism is being used for pipe diameter 300 mm ... 1200 mm (12” ... 48”) for pipe diameter >1200 mm ... 1800 mm (> 48” ... 72”) Versions for low-temperature range -196 ... +100°C on request Subject to change without notice For information about permissible sample gas pressure/temperature range, see also pg. 41, Fig. 7, pg. 42, Fig. 9, pg. 43, Fig. 11, pg. 44, Fig. 13. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 37 Product Description Suitability of materials for probe with transducer and seal NOTICE: ● "The suitability rating for sealing materials and transducer/probe materials given in the tables below refer to the specifications of the material manufacturer at room temperature. Finally the suitability of sealing material and transducer/probe material must be checked by the user considering the overall application conditions. Stainless steel configurations are suitable for non-aggressive and dry gas only. ● "Since the retraction flange is outside the pipeline behind ball valve and is not directly flowed through by the medium, it can be assumed that, as a result of the temperature drop, the permitted temperature limit for the seals are not exceeded when the temperature of the media is between min -196 °C and max +280 °C (temperature range of standard/high/low temperature version have to be considered). Medium 1) Air / like air HF O2 Water steam up to 100 °C Water steam up to 280 °C CH4 / Natural gas Sour gas CO2 Flare gas CL2 H2 NH4 Ultrasonic transducer material SS Ti HS 2) +++ +++ +++ — — +++ +++ + +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ + +++ +++ +++ +++ +++ +++ +++ +++ + — +++ +++ + +++ +++ +++ +++ 1: Rated gas temperature and MWP see marking plate Available on request +++: very good ++: good +: conditional good SS: stainless steel group 4 Ti: titanium grade 2 / grade 5 2): Subject to change without notice —: not suitable HS: hastelloy 38 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description Medium 1) Air / like air HF O2 Water steam up to 100 °C Water steam up to 280 °C CH4 / Natural gas Sour gas CO2 Flare gas CL2 H2 NH4 Sealing material in the retraction flange 2) FKM EPDM FFKM PTFE Viton TM Vistalon TM Kalrez TM Teflon TM temp. range temp. range temp. range temp. range -40 ... +180 °C -50 ... +100 °C -15 ... +280 °C -196 ... +280°C +++ +++ +++ +++ +++ — +++ +++ ++ + +++ +++ — +++ +++ +++ — — +++ +++ +++ — +++ +++ + +++ +++ +++ +++ + +++ +++ +++ +++ +++ +++ ++ — +++ +++ +++ +++ +++ +++ — +++ +++ +++ 1: Rated gas temperature and MWP see marking plate For retractable ultrasonic transducers only. indicated in the type code Leaking O-rings may only be changed by SICK service. +++: very good ++: good +: conditional good —: not suitable Subject to change without notice 2): FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 39 Product Description 2.2.1.2 FLSE100-EXS sender/receiver units Transducers: small version Process connection: prepared for mounting on counter flange 2" CL150 RF acc. to ASME B16.5 or counter flange DN50 PN16 form B1 acc. to EN 1092-1 I) FLSE100-EXS sender/receiver units according to ATEX for use in zone 2 only Explosion protection: ATEX II 3 G Ex nA IIC T4 Gc Applied standards: EN 60079-0, EN 60079-15 NOTICE: Future devices will also be labelled according to EN 60079-0:2012. The previous label is still valid. 1 Non-retractable version Fig. 6 FLSE100-EXS sender/receiver units, non-retractable version Probe with 2-channel electronics (master) Probe without electronics (slave) Subject to change without notice Connection to master probe Modules/parts not named: pg. 31, Fig. 5 40 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description Fig. 7 Permissible sample gas pressure/temperature range Pressure in bar Range for standard temperature version Range for hightemperature version Temperature in °C NOTICE: Range for low temperature version see p. 45, Fig. 14. 2 Retractable version Fig. 8 FLSE100-EXS sender/receiver units, retractable version (guide rods not shown) Probe with 2-channel electronics (master) 1 2 3 Probe without electronics (slave) Subject to change without notice 1 2 4 Modules/parts not named: pg. 31, Fig. 5 1 Connection for optional venting2 3 Retraction flange4 Duct probe RE Connection to master probe FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 41 Product Description Fig. 9 Permissible sample gas pressure/temperature range Pressure in bar Range for standard temperature version Range for hightemperature version Range for standard temperature ball valve and retraction flange Temperature in °C Subject to change without notice NOTICE: Range for low temperature version see p. 45, Fig. 14. 42 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description II) FLSE100-EXS sender/receiver units certified according to ATEX for use in zone 1 and 2 Explosion protection: ATEX II 1/2 G Ex de[ia] IIC T4, optionally T6 with reduced ambient temperature range ( pg. 202, § 6.1) 1 Non-retractable version Fig. 10 FLSE100-EXS sender/receiver units, non-retractable version Probe with 2-channel electronics (master) Applied standards: 1 EN 60079-0, EN 60079-1, EN 60079-7, EN 60079-11, EN 60079-26 2 Probe without electronics (slave) Applied standards: EN 60079-0, EN 60079-11, EN 60079-26 3 Modules/parts not named: pg. 31, Fig. 5 1 Electronic unit in Exd housing 2 Connection Ex ia to slave probe 3 Connection Ex ia to master probe Fig. 11 Permissible sample gas pressure/temperature range Subject to change without notice Pressure in bar Range for standard temperature version Range for hightemperature version Temperature in °C NOTICE: Range for low temperature version see p. 45, Fig. 14. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 43 Product Description 2 Retractable version Fig. 12 FLSE100-EXS sender/receiver units, retractable version (guide rods not shown) Probe with 2-channel electronics (master) Applied standards: EN 60079-0, EN 60079-1, EN 60079-7, EN 60079-11, EN 60079-26 1 2 4 3 5 Probe without electronics (slave) Applied standards: EN 60079-0, EN 60079-11, EN 60079-26 2 6 Modules/parts not named: pg. 31, Fig. 5 5 1 Electronic unit in Exd housing 2 Connection for optional venting 3 Duct probe RE Fig. 13 3 4 Connection Ex ia to slave probe 5 Retraction flange 6 Connection Ex ia to master probe Permissible sample gas pressure/temperature range Pressure in bar Range for hightemperature version Range for standard temperature ball valve and retraction flange Temperature in °C NOTICE: Range for low temperature version see p. 45, Fig. 14. 44 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Range for standard temperature version Product Description Low temperature versions Permissible sample gas pressure/temperature range for sender/receiver units in low temperature version, retractable and non-retractable versions Subject to change without notice Figure 14 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 45 Product Description III) FLSE100-EXS sender/receiver units certified according to ATEX and IECEx for use in zone 1 and 2 and CSA approved Cl I Div1/Div2 Explosion protection: ATEX II 1/2 G Ex d[ia] IIC T4, CSA Cl I, Div1/Div2 groups BCD T4, IECEx Ga/Gb Ex d[ia]IIC T4, optionally T6 with reduced ambient temperature range ( pg. 202, § 6.1) Applied standards: EN 60079-0, EN 60079-1, EN 60079-11, EN 60079-26, respective IEC standards C/UL standards 1 Non-retractable version Permissible sample gas pressure/temperature range: pg. 43, Fig. 11 Fig. 15 FLSE100-EXS sender/receiver units Probe with 2-channel electronics (master) 1 2 Probe without electronics (slave) Applied standards: EN 60079-0, EN 60079-11, EN 60079-26 3 46 Modules/parts not named: pg. 31, Fig. 5 Subject to change without notice 1 Electronic unit in Exd housing 2 Connection Ex ia to slave probe 3 Connection Ex ia to master probe FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2 Retractable version Permissible sample gas pressure/temperature range: pg. 44, Fig. 13 Fig. 16 FLSE100-EXS sender/receiver units, retractable version (guide rods not shown) Probe with 2-channel electronics (master) 1 2 4 3 5 Probe without electronics (slave) Applied standards: EN 60079-0, EN 60079-11, EN 60079-26 Modules/parts not named: pg. 31, Fig. 5 6 Connection Ex ia to slave probe Retraction flange Connection Ex ia to master probe Subject to change without notice 1 Electronic unit in Exd housing4 2 Connection for optional venting5 3 Duct probe RE6 5 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 47 Product Description 2.2.1.3 FLSE100-EX and FLSE100-EXRE sender/receiver units Transducers: medium dimensions Process connection: prepared for mounting on counter flange 2" CL150 RF acc. to ASME B16.5 or counter flange DN50 PN16 form B1 acc. to EN 1092-1 I) FLSE100-EX and FLSE100-EXRE sender/receiver units according to ATEX for use in zone 2 only Explosion protection: ATEX II 3 G Ex nA IIC T4 Gc Applied standards: EN 60079-0, EN 60079-15 Fig. 17 FLSE100-EX and FLSE100-EXRE sender/receiver units FLSE100-EX sender/receiver unit, non-retractable version Permissible gas pressure/temperature range: pg. 41, Fig. 7 FLSE100-EXRE sender/receiver unit, retractable version (guide rods not shown) 1 3 2 Permissible gas pressure/temperature range: pg. 42, Fig. 9 Modules/parts not named: pg. 31, Fig. 5 Subject to change without notice 1 Connection for optional venting 2 Retraction flange 3 Centering 48 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description II) FLSE100-EX and FLSE100-EXRE sender/receiver units certified according to ATEX for use in zone 1 and 2 Explosion protection: ATEX II 2 G Ex de IIC T4, optionally T6 with reduced ambient temperature range ( pg. 202, § 6.1) Applied standards: EN 60079-0, EN 60079-1, EN 60079-7 Fig. 18 FLSE100-EX and FLSE100-EXRE sender/receiver units FLSE100-EX sender/receiver unit, non-retractable version 1 Permissible gas pressure/temperature range: pg. 43, Fig. 11 FLSE100-EXRE sender/receiver unit, retractable version (guide rods not shown) 1 2 3 5 4 Permissible gas pressure/temperature range: pg. 44, Fig. 13 Retraction flange Centering Modules/parts not named: pg. 31, Fig. 5 Subject to change without notice 1 Electronic unit in Exd housing4 2 Connection for optional venting5 3 Duct probe RE FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 49 Product Description III) Sender/receiver units certified according to ATEX and IECEx for use in zone 1 and 2 and CSA approved Cl I Div1/Div2 Explosion protection: ATEX II 2 G Ex d IIC T4, CSA Cl I, Div1/Div2 groups BCD T4, IECEx Ex d IIC T4, optionally T6 with reduced ambient temperature range ( pg. 202, § 6.1) Applied standards: EN 60079-0, EN 60079-1, resp. IEC standards C/UL standards Fig. 19 FLSE100-EX and FLSE100-EXRE sender/receiver units FLSE100-EX sender/receiver unit, non-retractable version 1 Permissible gas pressure/temperature range: pg. 43, Fig. 11 FLSE100-EXRE sender/receiver unit, retractable version (guide rods not shown) 1 2 3 5 4 Permissible gas pressure/temperature range: pg. 44, Fig. 13 Retraction flange Centering Modules/parts not named: pg. 31, Fig. 5 Subject to change without notice 1 Electronic unit in Exd housing4 2 Connection for optional venting5 3 Duct probe RE 50 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2.2.1.4 FLSE100-EXPR sender/receiver units Transducers: small size Process connection: prepared for mounting on counter flange 3" CL150 RF acc. to ASME B16.5 or counter flange DN80 PN16 form B1 acc. to EN 1092-1 I) FLSE100-EXPR sender/receiver unit according to ATEX for use in zone 2 only Explosion protection: ATEX II 3 G Ex nA IIC T4 Gc Applied standards: EN 60079-0, EN 60079-15 Fig. 20 FLSE100-EXPR sender/receiver units Non-retractable version Permissible gas pressure/temperature range: pg. 41, Fig. 7 Retractable version (guide rods not shown) 1 2 Permissible gas pressure/temperature range: pg. 42, Fig. 9). NOTICE: Maximum pressure for use of retraction mechanism: 0.5 barg Modules/parts not named: pg. 31, Fig. 5 Subject to change without notice 1 Connection for optional venting 2 Retraction flange FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 51 Product Description II) FLSE100-EXPR sender/receiver unit certified according to ATEX for use in zone 1 and 2 Explosion protection: ATEX II 1/2 G Ex de[ia] IIC T4 optionally T6 with reduced ambient temperature range ( pg. 202, § 6.1) Applied standards: EN 60079-0, EN 60079-1, EN 60079-7, EN 60079-11, EN 60079-26 Fig. 21 FLSE100-EXPR sender/receiver unit for ATEX zone 1 and 2 Non-retractable version 1 Permissible gas pressure/temperature range: pg. 43, Fig. 11 1 Retractable version (guide rods not shown) 2 3 Permissible gas pressure/temperature range: pg. 44, Fig. 13). NOTICE: Maximum pressure for use of retraction mechanism: 0.5 barg Modules/parts not named: pg. 31, Fig. 5 Subject to change without notice 1 Electronic unit in Exd housing 2 Connection for optional venting 3 Retraction flange 52 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description III) FLSE100-EXPR sender/receiver unit certified according to ATEX and IECEx for use in zone 1 and 2 and CSA approved Cl I Div1/Div2 Explosion protection: ATEX II 1/2 G Ex d [ia] IIC T4, CSA Cl I, Div1/Div2 group BCD T4, IECEx Ga/Gb Ex d[ia]IIC T4, optionally T6 with reduced ambient temperature range ( pg. 202, § 6.1) Applied standards: EN 60079-0, EN 60079-1, EN 60079-11, EN 60079-26, respective IEC standards C/UL standards Fig. 22 FLSE100-EXPR sender/receiver unit for ATEX, CSA and IEC Non-retractable version 1 Permissible gas pressure/temperature range: pg. 43, Fig. 11 Retractable version (guide rods not shown) 1 2 3 Permissible gas pressure/temperature range: pg. 44, Fig. 13). Subject to change without notice NOTICE: Maximum pressure for use of retraction mechanism: 0.5 barg 1 Electronic unit in Exd housing 2 Connection for optional venting 3 Retraction flange FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Modules/parts not named: pg. 31, Fig. 5 53 Product Description 2.2.2 Mounting accessories Sender/receiver units are fitted to the pipeline using the following material: Fig. 23 Mounting accessories (according to ANSI CL150; example with nozzle 2" Long Welding Neck") Ball valve (only for retractable sender/receiver unit) Seal Blind ( flange Connection piece A Blind flange not shown) Bevel for welding Path angle 90 ° Marking VL L (Pipeline) Connection ANSI CL150 2" or 3” View A for path angle 75 ° 75 ° Subject to change without notice NOTICE: Use of mounting accessories for standard temperature range -70...+180 C: ● The ball valve must not be insulated for media temperatures below -40 °C or higher than +160°C. ● For gas temperatures below -40 °C or higher than +180°C, the temperature at the nozzle flange must be checked after through-heating during initial start-up. If required, the nozzle insulation must be removed as required to stay in the specified temperature limit. ● Do not exceed temperature and pressure ranges as listed in p. 55, 2.2.2.1. Material for use outside this specification is available as option or on request. 54 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2.2.2.1 Nozzles, blind flanges and seals The nozzles are an integrated part of the measurement system depending on the type: – For FLOWSIC100 EX-S/EX/EX-RE: Nozzles of type "Long Welding Neck" – For FLOWSIC100 EX-PR: Nozzles of type "Long Welding Neck" Other nozzle types (latro, heavy barrel) are available as an option. Nozzles are delivered with factory adaption to the nominal pipe diameter, bevel for welding and marking for nozzle alignment according to the gas flow. Nozzle, blind flange and seal according to ANSI Component Nozzle Nozzle CL150 2" CS 90° NozzleCL150 2" CS 75° Nozzle CL150 3" CS 75° Blind flange Blind flange CL150 2" CS Blind flange CL150 3" CS Seal 2" Seal B9A 2" 150 1.4571 3) Seal 3" Seal B9A 3" 150 1.4571 3) 1): 2): 3): 4): Connection Material (ASTM) max. pressure 4) L [mm] CL150 2" Carbon steel A105 16 bar @ -10 ... +100 °C 133,5 FLSE100-EXS 181,0 FLSE100-EX/EXRE 182,0 2) FLSE100-EXPR Carbon steel A105 16 bar @ -10 ... +100 °C - CL150 2" Stainless steel 316 L or 316 Ti, graphite 16 bar @ -196 ... +280 °C - CL150 3" Stainless steel 316 L or 316 Ti, graphite 16 bar @ -196 ... +280 °C - CL150 3" CL150 2" CL150 3" 1) Use for FLSE100-EXS, EXRE/EX FLSE100-EXPR FLSE100-EXS, EX, EXRE FLSE100-EXPR Take into account additional 3 mm ”welding space” for nozzles of type "Long Welding Neck" Nozzle length 212,0 mm for pipe size 12” Other sealing material on request According to diagrams of pressure/temperature ranges (e.g. pg. 41, Fig. 7) Subject to change without notice ● Seals must be chosen in accordance with application conditions (gas temperature). ● An optional insulation set with polymer seals and sleeves for bolts is available FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 55 Product Description Nozzle, blind flange and seal according to DIN Component Nozzle Nozzle PN16 DN50 CS 90° Nozzle PN16 DN50 CS 75° Nozzle PN16 DN80 CS 75° Blind flange Blind flange PN16 DN50 CS Blind flange PN16 DN80 CS Seal 2" Seal B9A PN16 DN50 1.4571 3) Seal 3" Seal B9A PN16 DN80 1.4571 3) 1): 2): 3): Material max. pressure 4) L [mm] PN16 DN50 Carbon steel P350GH 16 bar @ -10 ... +100 °C PN16 DN80 A105 (ASTM) 161,5 FLSE100-EXS 209,0 FLSE100-EX/EXRE 205,0 2) FLSE100-EXPR PN16 DN50 PN16 DN80 Carbon steel P350GH 16 bar @ -10 ... +100 °C - PN16 DN50 Stainless steel 316 16 bar absolute @ L or 316 Ti, graphite -196 ... +280 °C - PN16 DN80 Stainless steel 316 16 bar absolute @ L or 316 Ti, graphite -196 ... +280 °C - 1) Use for FLSE100-EXS, EXRE/EX FLSE100-EXPR FLSE100-EXS, EX, EXRE FLSE100-EXPR Take into account additional 3 mm ”welding space” for nozzles of type "Long Welding Neck" Nozzle length 235 mm for pipe size 12” Other sealing material on request According to diagrams of pressure/temperature ranges (e.g. pg. 41, Fig. 7) Subject to change without notice 4): Connection 56 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2.2.2.2 Ball valve Ball valves are only required for retractable sender/receiver units. Ball valve according to ANSI Component Connection Standard Temperature Ball valve CL150 2" CL150 2" SS Ball valve CL150 3" CL150 3" SS High Temperature Ball valve CL150 2" CL150 2" SS Ball valve CL150 3" CL150 3" SS Low temperature Ball valve CL150 2" CL150 2" SS Ball valve CL150 3" CL150 3" SS Material (ASTM) Gas temperature range Stainless steel 1.4408 (CF08M) -50 … +200 °C Stainless steel 1.4408 (CF08M) -50 … +350 °C Stainless steel A182 F316 Ti / A351 (CF08M) -196 … +100 °C Max. pressure 16 bar @ -10 ... +150 °C 16 bar @ -10 … +150 °C 16 bar @ -196 … +20 °C VL [mm] Use for 178 FLSE100-EXS, EXRE 203 FLSE100-EXPR 178 FLSE100-EXS, EXRE 203 FLSE100-EXPR 178 FLSE100-EXS, EXRE 203 FLSE100-EXPR VL [mm] Use for 150 FLSE100-EXS, EXRE 180 FLSE100-EXPR Ball valve according to DIN Component Connection Material (ASTM) Standard Temperature1 Ball valve PN16 DN50 Stainless steel 1.4408 PN16 DN50 SS Ball valve PN16 DN80 PN16 DN80 SS -50 … +200 °C Max. pressure 16 bar @ -10 ... +150 °C (acc. EN 1092-1, table 4.4.1-4) High and low temperature ball valves acc. to DIN on request. Subject to change without notice 1 Gas temperature range FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 57 Product Description 2.2.3 Nozzle installation tool The installation tool serves to align and weld the nozzle on the pipeline. It consists of: – welding aid M16 75 °(1) or welding aid M16 90 °(5), – centering plate 2” (2) or centering plate 3” (6), – threaded rod M16 length 290 mm (3), – centering 2”/3” (4), – installation paper strip as tool to determine the exact nozzle position on the pipeline. Fig. 24 Nozzle installation tool Design for FLOWSIC100 EX-S 1 4 3 2 Nozzle Marking Pipe wall Design for FLOWSIC100 EX / EX-RE 4 3 2 5 Design for FLOWSIC100 EX-PR 3 6 Subject to change without notice 4 5 58 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2.2.4 MCUP control unit Subject to change without notice The control unit has the following functions: ● Control of the data transfer and processing of the sender/receiver unit data connected via the RS485 interface. ● Signal output via analog output (measured value) and relay outputs (device status) ● Signal input via analog and digital inputs ● Voltage supply of the connected sender/receiver units ● Communication with higher level control systems via optional modules Plant and device parameters can be set easily using a laptop and user friendly operating program via: – Service interface USB 1.1 or RS232 – Service interface RS485 (standard for ex-protected MCUP) The parameters are stored reliably even in case of power failure. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 59 Product Description Versions Version Explosion protection / applied standards MCUP nonEx Housing type Power supply Cable entries Options Wall housing, compact size, painted steel 24 V d.c. 90 ... 250 V a.c. 4 x M20, 1x M16 (cable glands included); 1 x M25 (plug) 9x M20, 5x M25 (3 measuring points) - Wall housing, Medium size, painted steel NPT cable entries and flange plate connection, cable glands, painted stainless steel housing II 2 G Ex de IIC T6 Wall housing Ex-d 24 V d.c. 90 … 9 x M20, 5 x M25 (1 NPT cable entries, with Ex-e terminal 250 V a.c. or 2 measuring 3 measuring compartment, points), flange plate points, cable size 4 (type connection glands, painted STAHL), painted stainless steel aluminum housing Wall housing Ex-d with Ex-e terminal compartment, size 6 (type STAHL), aluminum MCUP CSA CSA Cl I, Div 1 Wall housing Exd, 100 … 240 V 3x3/4" NPT, 6x1/2" Cable glands size 4 (type a.c. NPT STAHL), painted 24 V d.c. aluminum Wall housing Exd, 5x3/4" NPT, 9x1/2" size 6 (type NPT STAHL), painted aluminum CSA Cl I, Div 2; Cl Wall housing, 24 V d.c. 115/ 9 x 1/2" NPT, 5 x 3/ Painted stainless I, zone 2 Medium size, 230 V a.c. 4" NPT (3 measursteel housing, painted steel automatically cable glands ing points), flange controlled plate connection 1): 60 not applicable for USA and Canada FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice MCUP ATEX1) 19” rack, aluminTerminals ium II 3 G Ex nA IIC T4 Wall housing, 24 V d.c. 115/ 9 x M20, 5 x M25 (3 Gc Medium size, 230 V a.c. measuring points) painted steel automatically controlled NPT cable entries and flange plate connection, cable glands, painted stainless steel housing - Product Description Fig. 25 MCUP control unit (example medium size wall housing) Processor board LC-Display POWER LED Control buttons Meas Hat rail for optional I/O and interface modules Standard interfaces (without optional modules) Analog output 1 output 0/2/4 ... 22 mA (active) for optional output of measured variables: ● Velocity ● Volume flow a.c. ● Volume flow s.c. ● Temperature ● Mass flow ● Molecular weight Resolution 10 bits Analog inputs 2 inputs 0 ... 20 mA (standard; without electric isolation) for optional input of computation variables (temperature, pressure, humidity) Resolution 10 bits Relay outputs 5 changeover contacts 30 V a.c./d.c., 1 A) Status signals: ● Operation/malfunction ● Maintenance ● Check cycle ● Maintenance requirement ● Limit value/direction Digital inputs Communication 2 potential-free ● Service interface: contacts for: –USB 1.1 + RS232 ● Connection of a (on terminals) for maintenance switch MCUP non ex-pro● Triggering of a comtected plete check cycle –USB 1.1 + RS485 (on terminals) for MCUP ex-protected for measured value queries, setting of parameters and software updates ● RS485 for sensor connection Subject to change without notice Display module Module to display measured values and status information of the connected sender/ receiver unit(s), selection via control buttons. – Displays The graphic display shows two main measured values preselected at the factory of a connected pair of sensors by means of a bar graph. Alternatively, up to 8 single measured values of a sender/receiver unit can be displayed. Type LED Power (green) Failure (red) Maintenance request (yellow) Display Power supply OK Function fault Maintenance requirement FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 61 Product Description LC-Display Graphic display (main screen) Text display Displayed values: – Volume flow in actual state (Q.act.), – Volume flow in standard state (Q.std.), – Gas velocity (VoG), – Speed of sound (SoS), – Transducer temperature A (T A), – Transducer temperature B (T B), – Signal-noise ratio A (SNR A), – Signal-noise ratio B (SNR B), – Mass flow – Molecular weight Max. 8 measured values (see graphic display) – Control buttons Button Meas Arrows Status Menu Fig. 26 Function – Select the single measured value to be shown – Toggle between text and graphic display – Display the contrast setting (after 2.5 s) Select next/previous measured value page Display alarm or fault message Display main menu LC-Display QiB VoG SoS T ak. TA TB 120000.00 m³/h 65.04 m/s 334.21 m/s 18.3 °C 17.6 °C 18.0 °C Subject to change without notice Menu 62 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description Optional modules MCUP non Ex MCUP ATEX MCUP ATEX MCUP CSA Cl I, MCUP CSA Cl I, Ex zone 2 Ex zone 1 Div2 / zone 2 Div1 Compact or 19” rack medium housing Module type Analog output module max. 3 pcs.; with two outputs 0/4 ... 22 mA of each one (max. load 500 Ω) Analog input module max. 2 pcs.; with two inputs 0/4 ... 22 mA of each one Digital output module max. 1 pc.; with 2x changeover contacts (load of 30 V a.c./d.c., 5 A; 30 V d.c., 2 A for Ex zone 2) 1 pc. module 1 pc. module 1 pc. module carrier per module carrier per carrier 19” for up Accessories required module to 8 modules for analog or digital modules 1 pc. connection cable Interface module Pulse, Ethernet + pulse, Ethernet triplex + pulse, MODBUS TCP + pulse, MODBUS RS485 + pulse, (max. 1 pc.) HARTBUS AO + pulse, PROFIBUS RS485 + pulse, Foundation Fieldbus + pulse NOTICE: The maximum number of analog modules is 4. Module carriers (MCUP non Ex with compact or medium housing) have to be positioned on hat rail ( pg. 61, Fig. 25). Subject to change without notice ● Profibus DP-V0 for transmission via RS485 according to DIN 19245, Part 3 as well as IEC 61158. ● The Modbus module supports MODBUS ASCII and MODBUS RTU according to "Modbus Application Protocol Specification V1.1b". ● Detailed specification for Modbus RS485 and HART® bus modules is contained on the Product CD (can be provided on request before system delivery). ● The pulse output is part of the interface modules to output the measuring values for actual volume, standard volume and mass (connection as "NAMUR" or "Open Collector" pg. 141, Fig. 73; configuration pg. 170, § 4.2.6). FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 63 Product Description Type code of Control Unit MCUP The following type codes define the various configuration options: Supply voltage Purge air supply Design/Description 90 ... 250 V a.c. 115/230 V a.c. (zone 2 only) Optional 24 V d.c. Not integrated Wall housing Compact, painted, SICK orange, SS 1.4016 or equivalent **) Wall housing Medium, painted, SICK orange, SS 1.4016 or equivalent, type 4 Case variant Housing Ex-d/Exe, painted, Al/St, size 4 (type STAHL) *) Housing Ex-d, painted, Al, size 4 (type STAHL) Housing Ex-d, painted, Al, size 6 (type STAHL) 19” rack **) 1 measuring point (1x1-path, Number of 1x2-path) measuring 2 measuring points (2x1-path) points 3 measuring points (3x1-path) No cable entries Housing cable entry Cable entries with metric thread Cable entries with NPT thread without Ex-Certification ATEX Zone 1, IIC T6 ATEX Zone 2 IIC T4 ExCSA Cl I, Div 1, T6 protection CSA Cl I, Div2, T4 INMETRO Zone 1 INMETRO Zone 2 Analog input Without optional module, option 2 x AI on board (additional 1 analog input module to 2 AI‘s incl. in standard) 2 analog input modules Without optional module, 1 x AO on board 1 analog output module Analog out- 2 analog output modules put option 3 analog output modules (2 outputs Digital transmitter interface (HART) per module) 1 analog input module, digital transmitter interface (HART) 2 analog input modules, digital transmitter interface (HART) Without optional modules, Digital input 2 x DI on board option 1 digital input module (4 inputs per (not yet available) module) 2 digital input modules (not yet available) 64 MCUP- X W S 2 X X Type code for control unit process X X X X X X X X X X X X N A B D K L F 1 2 3 N M C N A B D E F G 0 1 2 0 1 2 3 5 6 7 0 1 2 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Parameter Product Description Digital output W option (2 changeover contacts per module) Digital output S option (4 makecontacts per module) Optional Interface module Remote Interface Special Solution Without optional modules, 5 x relay contacts on board 0 1 digital output module 1 Without optional module 0 1 digital output module (not yet available) 1 without interface T/P-MOD RS485,MODBUS ASCII/ RTU,pulse T/P-MOD AO,HARTBUS,pulse T-MOD CONV HART FF,pulse (on request) T/P-MOD RS485,PROFIBUS,pulse T/P-MOD pulse T/P-MOD Ethernet V1,COLA-B, triplex,pulse T/P-MOD Ethernet V2,MODBUS TCP,pulse T-MOD CONV IF FF,pulse (on request) T-MOD CONV IF FF,PID,pulse (on request)*) Reserve RS485, COLA-B/MODBUS ASCII/ RTU T-MOD Ethernet V2,COLA-B, Service T-MOD Ethernet V2,MODBUS TCP, Service N M H F P A V Q B C R S W Q On request *): not applicable for CSA approved versions **): no explosion protection Subject to change without notice Example: MCUP-W N D 1 M A 0 1 0 0 0 M R N Power supply 90 ... 250 V a.c. no integrated purge air supply Ex-d housing one measuring point metric cable glands ATEX zone 1 T6 without analog input module with 1 analog output module without digital input module without digital output module W without digital output module S Modbus RS485 with pulse output module reserve without additional features FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 65 Product Description 2.2.5 Connection cables and cable glands Connection cables serve communication between sender/receiver units FLSE100 and between sender/receiver units and control unit MCUP. SICK offers standard cables and cable glands: a) Connection between sender/receiver units: – cable UNITRONIC® Li2YCYv (TP) with reinforced black outer sheath, fixed cable length – cable glands metric M20, NPT ½", material brass and stainless steel b) Connection between sender/receiver unit master and MCUP: – cable UNITRONIC® Li2YCYv (TP) with reinforced black outer sheath, meter good with free selectable lengths in steps of 5 m – cable glands metric M20, M25, NPT ½", NPT ¾", material brass and stainless steel Other connection cables for MCUP (power supply, outputs MCUP etc.) are not in the SICK scope of delivery. NOTICE: Factory pre-installed cable glands at S/R units and MCUP Install only fixed cables and wires in the cable glands. The plant operator must ensure an appropriate strain relief. The cable and conduit entries must be installed with mechanically protection against inadmissible impact energy according to EN 60079-0 section 26.4.2. NOTICE: Suitability of factory pre-installed plastic cable glands at MCUP ATEX Zone 2 In accordance with EN 60079-0, section 26.4.2 the pre-installed PA plastic cable glands at MCUP ATEX zone 2 are suitable for equipment group II with low degree of mechanical hazard (impact energy “low”, tested with drop height 0.4m or 4J). If there is a risk of higher mechanical stress, especially at low temperatures, the use of metal cable glands is recommended (available on request). Use for device type Remark FLOWSIC100 EX-S for analog connection Ex-d cable glands must be fitted to cables for sender/receiver units FLOWSIC100 EX, without an Exe terminal FLOWSIC100 EX-RE compartment. FLOWSIC100 EX-S, FLOWSIC100 EX, FLOWSIC100 EX-RE, FLOWSIC100 EXPR Ex-d cable glands must be fitted to cables for sender/receiver units without an Exe terminal compartment. Maximum length 500 m The maximum overall length of all cables of a measuring system (installation of 1 pair of s/r units) is up to 1,000 m. For cabling of 2-path or 3x1 path systems (installation with 2 pairs and 3 pairs of s/r units) the maximum possible cable length is reduced according to the number of pairs of s/r units (500 m for 2 pairs of s/r units, 300 m for 3 pairs of s/r units). 66 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Cable type Connection Length Cables for interconnection FLSE100 master - FLSE100 slave Analog cable Exi TNC at both ends 3m UNITRONIC single wires, tinned leads at both ends 5m Li2YCYv(TP), 10 m 2x2x0.5 mm² twisted pair Cables for interconnection FLSE100 master - MCUP single wires, tinned leads at both ends 5m 10 m UNITRONIC Li2YCYv(TP), 2x2x0.5 mm² twisted pair single wires at both ends yard good Product Description Specific requirements for selection and use of cables (esp. in hazardous areas) pg. 115, § 3.7.1. NOTICE: ● Only analog cable Exi of device type FL100 EX-S is approved for ATEX and CSA versions (interconnection of master and slave unit). ● All other cables offered by SICK are only for ATEX/IECEx versions for use in ATEX zone 1 or zone 2 applications. ● All cable glands offered are only for ATEX/IECEx versions for use in ATEX zone 1 or zone 2 applications. ● Cables, cable glands and other installation material for CSA Cl I, Div 1 versions must be provided by the customer. Solutions for CSA Cl I, Div2/zone 2 versions are available on request. Fig. 27 Connection cables FLSE100 Master Connection cable MCUP POWER Meas FLSE100 Slave Safe area Subject to change without notice Ex zone FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 67 Product Description 2.2.6 Meter body option (spoolpiece) The FLOWSIC100 Flare can also be fitted with an optional spoolpiece to reduce geometric uncertainty of device installation and to simplify assembly. The exact design (nominal diameter, connection, material) always depends on the customer specifications. The installation length of the spoolpiece depends on the nominal diameter of the pipe: – Installation length 800 mm for pipe diameter up to 28” – Installation length 1100 mm for pipe diameter 30” ... 60” – Installation length for pipe diameter >60‘‘...72‘‘ on request System solutions (FLOWSIC100 Flare + spoolpiece) are available as options with pressure and temperature transmitters. For the positioning of pressure and temperature transmitters the following configurations are available: – Spoolpiece, standard length with integrated pressure tapping, temperature sensor 3D downstream (customer pipeline) – Spoolpiece, extended length with integrated pressure and temperature tapping. Fig. 28 Spoolpiece option (example) Subject to change without notice 800 mm 68 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2.3 Computations 2.3.1 Calculation and calibration of volume flow Volume flow in operating state Generally, the devices of the FLOWSIC100 Flare family are used to determine the volume flow in closed pipelines. The volume flow Qac is defined by the representative crosssectional area A and the mean gas velocity vA with respect to cross-section (area velocity): Q ac = vA • A FLOWSIC100 Flare, however, determines the representative average value of the flow velocity on a sound path v (path velocity) between the two sender/receiver units. The sound path is to be placed centrally above the cross-section of the pipeline. Since the average values of path and area velocity are not identical, especially for small pipe diameters, a functional, systematic relation between the determined path velocity v and the average area velocity v A was introduced. vA k = f Re = -----------v Path 0.9 < k < 1 (Re = Reynolds‘ number) This functional relation is implemented by a calibrating function in the FLOWSIC100 Flare. The coefficients of this function are determined at factory through comparison measurement on a test bench and regression analysis, and stored in the MCUP control unit. The coefficients for various nominal pipe diameters are activated during start-up. The coefficients can be specified and entered into the measuring system by an optional flow calibration, and the measuring precision thereby improved even further. Calculation of volume flow in the standard state The volume flow can be converted as follows to the standard state: Subject to change without notice p pipe T normal 1 Q sc = Q ac ------------------------------------- -- p normal T pipe Q ac: Volume flow in actual state Q sc: Volume flow in standard state ppipe: Absolute pipeline pressure; usually entered as constant/default value typical for the equipment. If an optional analog module is used as an analog input for connection of a separate pressure transducer, the volume flow can be normalized with current plant values. pnormal: 1013 mbar Tpipe: Gas temperature (in K): In FLOWSIC100 Flare, a choice can be made here whether to use a substitute constant temperature determined with ultrasonic measurement or the substitute temperature read in via the optional analog input (to increase precision). Tnormal: Standard temperature. In Europe 273 K, in the USA 293 K : Compressibility (=1 for ideal gases); can be configured as a constant FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 69 Product Description 2.3.2 Mass flow and molecular weight determination The mass flow of the gas is computed from flow speed and sound velocity, pressure and further measured variables. The molecular weight of the gas is computed from sound velocity and further measured variables. The operating software uses three different algorithms to calculate mass flow and molecular weight: a) Basic algorithm: Uses a constant value for substance-dependent coefficient (adiabatic coefficient). b) Hydrocarbon algorithm: Determines according to the function relation to the standard sound velocity. Standard algorithm of FLOWSIC100 Flare for flaregas applications. c) Algorithm MR-113: Determines under consideration of the actual gas composition for hydrocarbon mixture. 2.3.3 Necessity for using external pressure and temperature transmitters The following table shows what calculations require use of external pressure and temperature transmitters. Calculation of External pressure transmitter External temperature transmitter Volume flow in standard state x x Mass flow x x Molecular weight — x Subject to change without notice General requirements ● Temperature transmitter: Pt100, 3- or 4-wires connection, head mounted transmitter, 2-wires Smart transmitter, explosion protected, output 4 ... 20 mA ● Pressure transmitter: Absolute pressure type, 1 ... 16 bar, 2-wires Smart transmitter, explosion protected, output 4 ... 20 mA 70 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2.3.4 Response time The response time is the time the measuring device requires to attain 90% of the end value after an abrupt change of the measured value ( Fig. 29). Typical values are 60 to 90 s. The response time is freely adjustable in the range 1...600 s. A higher response time causes higher damping of short-term measured value fluctuations and interference and thus a "smoothed" output signal. Separate response times exist for the measurement of gas velocity and gas temperature. Volume flow and gas velocity have the same response time. Fig. 29 Response time Measured value in% 100 90% of the signal peak 98 96 Measured value with response time 94 Process change 92 90 Response time 88 86 84 10 20 30 40 50 60 70 80 90 100 t in s Subject to change without notice The response time must be understood as a guide value only. If the signal quality of the ultrasonic pulses is low, FLOWSIC100 Flare requires more measured values for an output signal of the same precision. This increases the response time within certain limits as compared with the set time. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 71 Product Description 2. 4 Check cycle The FLOWSIC100 Flare is equipped with an integrated check cycle for automatic functional check of all device components. This check cycle is an approved tool for periodic device inspection according to valid regulations of Continuous Emission Monitoring. The check cycle can be triggered time-controlled (setting of interval time by means of an operating program) and/or manually via the digital input ( pg. 59, § 2.2.4). Any deviations from normal behavior that may occur are signaled as warnings or errors. A check cycle initiated manually can help to localize possible error causes should a device malfunction or a warning occur (see Service Manual). The check cycle comprises zero point control and span test. The control values can be output via the analog output. The sequence of a check cycle is indicated by the status output on the corresponding relay and, if the Display module option is available, simultaneously on the display by the clear text message "Check cycle". ● If the check cycle is not output on the analog output, the last measured value is output for the duration the check cycle duration (approx. 20 s in an error-free sequence). ● For initiation of zero point control and span test as well as a check cycle via the digital input, a contact at the respective terminals must be closed for at least 2 s. ● Time-controlled check cycles start periodically according to parameter setting of the desired time interval at the entered time until the time interval is changed (or a reset is performed). If a reset is made (or there is an operating voltage failure), the check cycle starts at the time the device is put into operation again at the set time. ● If a time-controlled check cycle and a check cycle initiated by digital contacts overlap, only the check cycle initiated first becomes effective. 2.4.1 Zero point control Subject to change without notice With a special circuit configuration in the sender/receiver units, the send-signals of the transducers can be read back without delay and in their original form. These send-signals are received, demodulated and computed as receive-signals. If the device functions correctly, the exact zero point must be calculated here. This control comprises the complete check of all system components including the transducers. For deviations of more than approx. 0.25 m/s (depending on active measuring path and gas temperature), a warning is output. Transducers and electronics must be checked in this case. If signal amplitude or form does not match the expected values, transducers or electronics are defective and an error message is output. 72 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Product Description 2.4.2 Span test For the electronic zero check, a time difference from both transfer directions is determined and computed with the air temperature, active measuring path and sound velocity installation parameters into a velocity offset at the zero point. This offset is then added to the selected span value and output. The span value can be set with the SOPAS ET operating program in the range from 50 to 70% in steps of 1% (standard setting ex factory 70%). If all system components are intact, the entire measuring system reacts as intended. 2.4.3 Analog output of check cycle The check cycle‘s output is as follows: ● 90 s zero value (live zero) ● 90 s span value Subject to change without notice ● The output duration of 90 s each time is the standard setting ex factory. It can be changed in the SOPAS ET program. ● The output is suitable for velocity-dependent measured values only (gas velocity, volume flow act., volume flow std.). FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 73 Subject to change without notice Product Description 74 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation FLOWSIC100 Flare 3 Assembly and Installation Subject to change without notice Project planning Assembly Installing non-retractable sender/receiver units Electrical installation FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 75 Assembly and Installation 3. 1 Project planning The following table provides an overview of the project planning work necessary as prerequisite for trouble-free assembly and subsequent device functionality. You can use this table as a checklist and check off the completed steps. Ensure that all safety warnings and notes in chapter 1 are observed. Task Determine measuring and installation locations ( pg. 77, § 3.1.1) Requirements Flow distribution, inlet and outlet paths Access, accident prevention Installation free of vibrations Lowest possible influence on the measuring precision Work step Follow specifications for new equipment; select best possible location for existing equipment Provide platforms or pedestals as required Eliminate/reduce vibrations through Acceleration < 1 g suitable measures If necessary: Limit values according to Technical Data in Provide weatherproof covers / sun protection, Ambient conditions pg. 202, § 6.1 enclose or lag device components. Internal pipe diameter Sender/receiver unit type Sender/receiver unit type (standard or Gas temperature high temperature version) Select Select components according to Gas composition Material of duct probe and transducer device Configuration Tables and Notes in pg. 31, components Fitting locations Cable lengths § 2.2. Access Distances to measuring level Operating voltage, power requirements Easy and safe No mutual interference between calibration probe and FLOWSIC100 Flare According to Technical Data in pg. 202, § 6.1 Provide platforms or pedestals as required Plan sufficient distance between measuring and calibration level (approx. 500 mm) Plan adequate cable cross-sections and fuses Subject to change without notice Plan calibration openings Plan power supply Easy and safe 76 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation 3.1.1 Determining the measuring and installation location Measuring precision is influenced, among other things, by flow behavior and the position of the measuring axis. Large cross-section variations, curved pipes, fittings, air flaps or inlets can cause profile deformations or turbulences with a negative effect on the measuring result. Fig. 30 Measuring and installation location Pipeline Possible installation area 10 Di Inlet path Outlet path 5 Di A Homogeneous flow profile Di Inhomogeneous flow profile Working platform Assembly nozzle General requirements Requirements Flow Position with essentially homogenous gas flow behaviour Balanced, uniform profiles are most likely to be expected for long inlet and outlet paths Pipeline Whenever possible, no deflections, cross-section variations, curves, feed and drain lines, flaps or design fittings in the area of the inlet and outlet paths Isometric conditions at measuring point are most important for determining the required upstream and downstream piping and should be investigated carefully. ● Uncritical flow inlet conditions requires straight upstream piping > 10 x Di and downstream piping > 5x Di. Manufacturer SICK offers expertise support for an optimal adjustment of the meter for the given inlet and outlet piping conditions. ● More complex inlet disturbances require longer pipings up to 20 Di/10 Di. Inlet and ● If the 2-path configuration is used, the needed minimum inlet and outlet sections can be further Measuring outlet path reduced compared to single path measurement with the same measurement uncertainty. location lengths ● For too short inlet/outlet paths: Inlet path > outlet path Pipelines with vertical, horizontal or inclined direction Installation free of vibrations, acceleration < 1 g Largest possible distance to control valves or other noisy fixtures Installation location With electrical connections and lighting Easy and safe access for installation and maintenance work of the sender/receiver units Platform secured by a railing to prevent accidents if necessary Working platform Sufficient clearance to fit/remove the sender/receiver units ● Maximum wall thickness 15 mm, maximum insulation thickness 100 mm. Larger wall and insulation thicknesses require customer-specific solutions (available on request only). Wall and insulation ● Minimum wall thickness depends on pressure, temperature, pipe size and static/dynamic load thickness at the measurement location (contact SICK for support). Nozzles may only be isolated if the gas temperature is < 100 °C. 3.1.1.1 Subject to change without notice Criteria FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 77 Assembly and Installation Follow specifications for new equipment; select best possible location for existing equipment. Contact SICK for optimal installation of the FLOWSIC100 Flare. NOTICE: The plant operator is responsible for observing the valid Accident Prevention and Industrial Safety Regulations. 3.1.1.2 Additional requirements for meter body option (spool piece) Requirements ● Same nominal size of adjacent pipes and meter body ● Differences of internal diameters of inlet pipe and meter body < 1%. Pipeline design ● No welding beads and burs on the flanges of the inlet pipe Pipelines with horizontal or vertical direction ● Horizontal installation: The meter body shall be aligned so that the planes formed by the measuring paths are in a horizontal position. This minimizes the problem of dirt in the pipeline entering the transducer ports. ● Vertical installation: Installation Only possible if the measuring system is used for dry, non-condensing gases. Gas flow Free from any foreign material, dust and liquids. Otherwise, filters and traps shall be used. Seals between meter Must not protrude into the pipeline. Any protrusion into the flowing gas stream may change the flow body and pipeline profile and thus the measuring accuracy may be adversely affected. Connection at the pressure tap provided with ⅛”, ¼”or ½” NPT (female) port, depending on meter size Pressure transmitter and customer demand. Fastening and sealing Bolts, nuts and flange seals used must be suited to the operational conditions and comply with legal material regulations and relevant standards. Subject to change without notice Criteria 78 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation 3.1.1.3 Clearance for fitting/removing the sender/receiver units Fig. 31 Clearance for fitting/removing the sender/receiver units Non-retractable version 1 2 a 4 Retractable version 1 1 2 3 4 2 3 Sender/receiver unit Nozzle Ball valve Pipeline b Sender/receiver units designed to fit counter flange CL150 RF acc. ASME B16.5 (Standard temperature version) NL Nonretractable 148 330 198 380 220 400 350 530 x Type FLSE100-EXS FLSE100-EX FLSE100-EXRE FLSE100-EXPR short FLSE100-EXPR long Retractable a b mm 700 inch 27.5 750 29.5 x x x x 1070 inch 1040 40.9 1250 49.2 1900 74.8 2050 80.7 42.1 x x mm 1200 47.2 x Sender/receiver units designed to fit counter flange DN PN16 (Standard temperature version) NL Subject to change without notice Type FLSE100-EXS FLSE100-EX FLSE100-EXRE FLSE100-EXPR short FLSE100-EXPR long 176 330 226 380 220 400 350 530 Nonretractable Retractable a mm 750 x b inch 29.5 x x 800 31.5 1070 42.1 1200 47.2 x x x x FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG x mm inch 1040 40.9 1250 49.2 1900 74.8 2050 80.7 79 Assembly and Installation 3.1.2 Further notes for project planning Applications with specific conditions or installation in vertical pipelines a) Applications with wet gas Condensate can accumulate in the nozzle pipes. The following solutions can help to prevent measurement problems (malfunctions caused by solid-borne noise, see Service Manual), or damages when removing the sender/receiver unit (condensate runs out). Use a nozzle position which prevents accumulations of condensates in nozzle pipes. Use a closed continuous or periodical condensate drain with backflow to the pipeline. Technical solutions are available on request depending on operating conditions (pressure, temperature). Installation of condensate drains always requires the approval of the plant operator. Isolate the nozzle pipe to reduce dew point underruns (only for low gas temperatures < 100 °C). b) Short inlet and outlet paths ( pg. 77, Fig. 30) Use the best possible positioning for the measurement path (consult SICK for support). c) Vertical ducts with flow direction from top to bottom The measured value gets a negative sign (output LC display). Set a negative linear regression coefficient ( pg. 190, § 4.3.7) to change it. Subject to change without notice Installation location for external pressure and temperature transmitters (option) Pressure tappings and thermowells for external transmitters have to be installed in the following way: ● Pressure tapping:direct at measurement point, on top side of pipeline ● Thermowell:downstream with distance 3D (measured from the middle of the measuring path), on top of pipeline 80 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation Notes for installation of sender/receiver units in 1-path, 2-paths or 3x1 path configuration 3.1.3 Cross-duct version Weld the assembly nozzles vertically (FLSE100-EXS) or at an angle of 75° (FLSE100-EX) with parallel offset onto the pipeline. FLSE100-EXS FLSE100-EX/EXRE Pipeline Probe offset Flow direction FLSE100-EXS Pipeline Probe offset Ultrasonic transducer FLSE100-EX/EXRE 75° Flow direction Ultrasonic transducer 1-path measurement 1-path measurement r r Assembly nozzle Assembly nozzle 2-path measurement 2-path measurement 0.6 •r 0.6 •r 0.6 •r 0.6 •r Special alignment of the ultrasonic transducer provides the angle to the flow axis required for measurement. Ensure that the sensors are facing each other. The parallel offset depends on the pipe diameter. The installation angle of the assembly nozzle and the parallel offset provide the angle to the flow axis required for measurement. The parallel offset depends on the pipe diameter. Probe version (FLSE100-EXPR) In order to capture a representative part of the flow, select the sender/receiver unit in a short or long version depending on the pipeline diameter (§2.2.1 Part „Application area, configurations“) and fit it as follows. Installation at vertical pipelines FLSE100-EXPR 75° Mounting direction prevents condensate accumulations in nozzle tube Subject to change without notice 1-path measurement Installation at horizontal pipelines Pipeline FLSE100-EXPR 75° Flow direction Assembly nozzle Pipeline r Flow direction Assembly nozzle 2-path measurement 0.6 •r 0.6 •r FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 81 Assembly and Installation 3. 2 Preparation work 3.2.1 General notes Check that the shipment contains all components ordered. Check the components for possible transport damages. Pay particular attention to transducer surfaces, sealing surfaces on the flanges and, if delivered, the interior of the meter body (spool piece). Immediately document and reported damages to the manufacturer. NOTICE: To guarantee safe and reliable operation of the measuring equipment, make sure that the actual site conditions match the information provided on the labels on sender/receiver units and control unit ( Fig. 32). Fig. 32 Main type plate on sender/receiver units Example device type FLSE100-EXS ATEX zone 1/IECEx 12 SICK Engineering GmbH, Bergener Ring 27, D-01458 Ottendorf-Okrilla 0044 FLSE100-EXS 00 FLSE100 Serial No.: 03 °C Tamb 04 °C 05 °C TGAS 06 °C Pmax@50°C 07 bar Pmax@ 06 °C 08 bar Flange size 09 IP 65/67 Made in Germany 01 Part No.: 02 II 1/2 G Ex d 10 [ia] 11 T 13 TÜV 09 ATEX 554975 Ga/Gb Ex d 10 [ia] 11 T 13 IECEx TUN 09.0015 UN = 15 ... 28 V DC, Um = 125 V For further details see Examination Certificate TÜV 09 ATEX 554975 Variable 00 01 02 03 04 05 06 07 08 09 10 11 12 Name Device type code Serial No. Part No. Min. ambient temperature Max. ambient temperature Min. gas temperature Max. gas temperature Max. operating pressure at 50 °C Max. operating pressure at Tgas max. (variable 06) Flange size „e” for terminal compartment option Ignition group Bar code Variable 00 01 02 03 04 05 06 07 08 09 10 11 12 82 Name Device type code Serial No. Part No. Min. ambient temperature Max. ambient temperature Min. gas temperature Max. gas temperature Max. operating pressure at 50 °C Max. operating pressure at Tgas max. (variable 06) Flange size Not relevant Not relevant Bar code FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Example device type FLSE100-EXS CSA Cl I, Div1 Group D Assembly and Installation 3.2.2 Special notes for handling the meter body option Transport and storage Secure for all transport and storage operations that: – the meter body is firmly secured at all times – measures are taken to avoid mechanical damage – ambient conditions are within the specified limits ( pg. 202, § 6.1). Protect sealing surfaces of the flanges and the interior of the meter body if it must be stored outside for more than one day, e.g. with Anticorit spray (not required for meter bodies from stainless steel). Do the same if the meter must be stored in dry condition, but for more than a week. Lifting requirements Fig. 33 Lifting requirements max. 60 ° Meter body option Subject to change without notice Flange sealing surface WARNING: Danger due to size and mass of the meter body Only use lifting gear and load handling equipment (e.g. lifting straps) which are suitable for the weight to be lifted. Max. load information can be found on the type plate of the lifting gear. Only use the eye bolts when lifting the meter body. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 83 Assembly and Installation 3. 3 Assembly Carry out all assembly work on-site. This includes: Fitting the nozzle Installing ball valves on retractable versions Installing the meter body (option) Installing the control unit. Installing the sun roof. WARNING: Observe the relevant safety regulations as well as the safety notices in Section 1 during all assembly work. Carry out assembly work on equipment with hazard potential (hot or aggressive gases, higher internal pipeline pressure) only when the equipment is at a standstill. Fitting when the equipment is running is only possible using the "hot tapping method". Such work may only be carried out by a specialized contractor authorized by the plant operator ( pg. 19, § 1.4). Take suitable protection measures against possible local hazards or hazards arising from the plant. Subject to change without notice WARNING: Mechanical burden The static load moment of all parts to be installed at the pipe can be up to approx. 600 Nm (retractable device types). Strong pipe vibrations can cause damages and can lead to dangerous situations. Use a mechanical support for the nozzles welded to the pipeline, e.g. "gusset plates". 84 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation Fig. 34 Option mechanical support for nozzle "gusset plates" Subject to change without notice Gusset plates NOTICE: The plant operator is responsible for the safety of the system under mechanical burden. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 85 Assembly and Installation 3.3.1 Fitting the nozzles on the pipeline (measuring systems without meter body) The nozzles are manufactured precisely at the factory according to customer specifications for fitting on the pipeline. NOTICE: The exact positioning of the nozzles is prerequisite for low measuring uncertainty. Maximum tolerances for nozzle positions and fitting angle of the nozzles: – Maximum tolerance ± 1 mm / ± 1 ° – Tolerance for best uncertainty results ± 0.1 mm / 0.1 ° Notes for installations in existing pipelines (hot tapping) ● For calculation of the precise inner diameter of the pipeline the wall thickness have to be determined very exactly. Schedule information alone is not sufficient. ● All exact geometric dimensions for fitting the nozzles in the pipeline (see following instructions) have to be documented during nozzle installation. At commissioning of the FLOWSIC100 Flare the geometric dimensions from the nozzle installation are needed for correct parameterization of the device. 3.3.1.1 Determining the nozzle positions and marking on the pipeline General preparation work The installation tool ( pg. 58, § 2.2.3) contains a foil strip (length approx. 4 times the pipe diameter, width approx. 0.75 of the pipe diameter) as a resource to determine the exact position of the nozzle on the pipeline. The foil strip is prepared with nozzle markings for different pipe diameters. Fig. 35 General preparation work 1) Wind the strip around the pipeline at the selected measuring point (ensure exact right-angled alignment) and secure (e.g. with adhesive strips). 2) Mark the strip where overlapping starts. Overlap line 86 U For 1 path measurements, fold the strip to the overlap line so that the part matching pipe circumference (U) is halved. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice 3) Loosen the fastening, take the strip off and lay it out on a level surface. Assembly and Installation Determining the nozzle position and marking on the pipeline for cross-duct types FLSE100-EXS and EX/EXRE Fig. 36 Determining the nozzle positions on the strip 1-path measurement 2-path measurement 4a) Roll the strip out again and mark the kink line. Overlap line U/2 Kink line 90 ° 4b) Roll the strip out again and mark the lines as follows: 2.498•r 0.6435•r 90 ° 90 ° 90 ° 2.498•r 90 ° 0.6435•r r = D/2 ( pg. 81, § 3.1.3) 90 ° 90 ° 5) Draw guide lines (1) for the nozzle positions in a distance as listed in the table, mark the crossing points (2) and draw marking points (3) in distance 60 mm (x) from the crossing points. U U/21 x x x Subject to change without notice mm 102 127 152 203 254 305 356 406 457 508 559 610 660 711 762 813 864 914 1067 1219 a x x 2 inch 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 42 48 Path 1Path 2 a x x Outside diameter x 2 3 Nozzle offset a FLSE100-EXS FLSE100-EX/EXRE mm inch mm inch 32.0 1.25 37.5 1.48 44.0 1.72 55.0 2.17 50.0 1.94 67.0 2.64 61.5 2.42 78.5 3.08 72.5 2.86 85.5 3.36 79.5 3.14 96.5 3.80 91.0 3.58 108.0 4.24 102.5 4.03 119.0 4.68 113.5 4.47 130.5 5.13 125.0 4.91 141.5 5.57 136.0 5.35 147.5 5.80 158.5 6.24 170.0 6.68 182.0 7.13 192.5 7.57 203.5 8.02 237.5 7.35 271.0 10.68 6a )Measure and note values a and U/2 (needed to calculate the path angle and path length). Outside diameter inch 12 14 16 18 20 22 24 26 28 30 32 34 36 42 48 52 56 60 64 68 72 mm 305 356 406 457 508 559 610 660 711 762 813 864 914 1067 1219 1321 1422 1524 1626 1727 1829 3 1 Nozzle offset a FLSE100-EXS FLSE100-EX/EXRE mm inch mm inch 64.0 2.52 58.0 2.30 70.0 2.76 64.0 2.51 79.0 3.11 73.0 2.87 88.0 3.46 82.0 3.22 97.0 3.82 91.0 3.58 106.0 4.17 100.0 3.93 115.0 4.53 109.0 4.29 118.0 4.64 127.0 5.00 136.0 5.35 145.0 5.71 154.0 6.06 163.0 6.42 190.0 7.48 217.0 8.54 235.0 9.25 253.0 9.96 271.0 10.67 289.0 11.38 307.5 12.10 325.0 12.80 6b) Measure and note values a and U (needed to calculate the path angle and path length). FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 87 Assembly and Installation Fig. 37 Marking the nozzle positions on the pipeline 1-path measurement 2-path measurement 7) Roll the strip back around the pipeline and mark the nozzle positions with crossing and marking points by using a metal center punch. Path 1 Path 2 Crossing point (marking for the center of the nozzle Marking point (aid for aligning the nozzle Crossing point (marking for the center of the nozzle Marking point (aid for aligning the nozzle Path 1 Path 2 8) Take the strip off again and join the additional markings with a line. Marking lines Subject to change without notice Marking lines 88 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation Determining the nozzle position(s) and marking on the pipeline for probe type FLSE100EXPR Fig. 38 Determining the nozzle position(s) 1-path measurement 2-path measurement 1) Start preparation work as shown in pg. 86, Fig. 35. 2a) Roll the strip out again and mark the kink line. Overlap line U/2 2b) Roll the strip out again and mark the lines as follows: Kink line 90 ° r = U/2 2.498•r 90 ° 90 ° 2.498•r 90 ° 90 ° 3) Draw a guide line (1) for the nozzle position(s), mark the crossing points (2) and draw marking points (3) in distance 80 mm (x) from the crossing points. U/2 x x 2 3 U 1 x x x x x 2 1 Path 2 Subject to change without notice Path 1 3 x FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 89 Assembly and Installation Figure 39 Marking the nozzle position(s) on the pipeline 1-path measurement 2-path measurement 6) Roll the strip back around the pipeline and mark the nozzle positions with crossing and marking points by using a metal center punch. Path 1 Path 2 Crossing point (marking for the center of the nozzle Marking point (aid for aligning the nozzle Crossing point (marking for the center of the nozzle Marking point (aid for aligning the nozzle Path 1 Path 2 7) Take the strip off again and join the additional markings with a line. Marking lines Subject to change without notice Marking lines 90 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation 3.3.1.2 Weld on nozzles for non-retractable sender/receiver units Use the installation tool that corresponds to the nozzle to be welded on the pipeline to carry out the following work. WARNING: Hazards due to combustible gases or high pressure Depressurize the pipe line and make free of flammable gases before starting any operation. WARNING: Risk of explosion/health hazard A faulty welding seam can allow gas to escape from the pipeline. This can immediately lead to a dangerous situation. Ensure welding seams are gas-tight. Check strength and durable tightness of the welding seams. NOTICE: Welding work may only be carried out by qualified personnel acc. to qualified and approved procedures. Inspections of the welded seam regarding correctness and pressure tightness of the design need to be made. The general safety requirements of relevant regulations, general standards and guidelines as well as plant operator instructions concerning execution and inspections of welding must be observed. Subject to change without notice Work steps Position the welding aid (1) on the pipeline (2) as shown in the following figure. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 91 Assembly and Installation Fig. 40 Positioning of the welding aid View B A 1 View A 2 Marking lines Flow direction 1 2 3 1 2 3 Welding aid Pipeline Threaded rod Angle 90 ° 75 ° Type FLSE100 FLSE100-EXS FLSE100-EXPR, FLSE100-EX, FLSE100-EXRE NOTICE: Check the welding aid position after welding. The deviation from the drawn lines must not be more than 0.5 mm. Otherwise reposition the welding aid. Screw in threaded rod (3) with the sharp tip in the welding aid. Slide centering plate (4) on the cone of the welding aid (1) and fasten with the nut (5). Slide nozzle (6) over threaded rod and centering plate. Place the centering (7) into the nozzle opening so that the marking on the centering corresponds to the nozzle type (ANSI or DIN, size). Screw counternuts (8), (9) onto the threaded rod and secure the nozzle at a distance of approx. 2 mm to the pipeline surface (use uncoated wire). Align the nozzle so that the marking lines on nozzle and pipe wall are flush and tighten enough so that the nozzle is pressed against uncoated wire and pipeline surface. Make sure the nozzle remains aligned correctly. 92 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice NOTICE: The threaded rod is fitted by the manufacturer with a clamp ring. This is to aid removal of the centering plate following installation of the nozzles. The clamp ring should therefore not be removed. Assembly and Installation Fig. 41 Fitting the nozzle 10 4 5 6 7 8 9 1 1 4 5 6 7 8,9 10 Welding aid Centering plate Nut Nozzle Centering Counter nuts Clamp ring Marking lines Weld the nozzle to the pipeline (seam length approx. 15 mm). Wait at least 1 minute after each welding to allow the seam to cool down before welding the next point. Remove uncoated wire. Remove threaded rod with nuts and centering by turning the counternut (8) against fastening direction. The centering plate will be removed by the clamp ring. Finish off each weld seam and allow sufficient time for cooling down to avoid unnecessary strain on the nozzle and pipe wall. On FLOWSIC100 Flare cross-duct versions (FLSE100-EX and FLSE100-EXS) and after sufficient time for cooling down, determine distance D1 between outer pipe wall and centering. Fig. 42 Determining of effective nozzle length (Nozzle) Centering Subject to change without notice D1 On cross-duct versions, weld the nozzle on the opposite pipeline side in the same manner and then determine distance D2. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 93 Assembly and Installation 3.3.1.3 Weld on nozzles for retractable sender/receiver units and drill out the pipeline Weld on the nozzles for retractable sender/receiver units in the same manner as described previously for non-retractable sender/receiver units and determine the distances D1 and D2 for cross-duct versions. For use of retractable sender/receiver units ball valves have to be installed. Ball valves are installed after finishing nozzle welding. Check and ensure gas tightness of ball valve installation before you continue. WARNING: Hazards through leaks! Operation in leaky condition is not allowed and possibly dangerous. Danger by explosive, toxic and hot gas! NOTICE: ● Any welding and installation work on pipelines may only be carried out by authorized personnel with a specific qualification. ● Special qualified and approved procedures have to be followed. This procedure requires the written agreement by the plant operator ( pg. 11, § 1.2.1). ● Inspection of welded seams and all other installation regarding correctness and pressure tightness need to be made. The general safety requirements and all other plant operator instructions have to be followed (see notice pg. 91, § 3.3.1.2). Drilling holes into the pipeline if plant is out of operation The pipe wall must be drilled out at the nozzle position so that the sender/receiver unit can be inserted into the pipeline ( pg. 86, § 3.3.1). ● Only once on each nozzle. ● Have this work done by skilled persons specially qualified for this work. WARNING: Hazards during hot tapping! When sender/receiver units are installed on the pipeline when the pipeline is in operation (hot tapping): Only have this work done by skilled persons qualified for hot tapping. Comply with all legal, general and company-internal regulations. Only start installation work when all planned measures have been checked and approved by the plant operator. 94 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Drilling holes into the pipeline if plant is in operation (hot tap) ● Only once on each nozzle. ● This work requires special tools (e.g. special drilling tool) and special technical knowledge. ● The hole cutter diameter must be 46 ... 48 mm for 2“ nozzles and 73 ... 75 mm for 3” nozzles. ● Mount the drilling tool on the ball valve. Check for installation. Open the ball valve and drill out the holes in the pipeline in the centre of the nozzle position. ● Retract the drilling tool. Dismount drilling tool after ball valve is closed again. ● Mount a blind flange on the ball valve as long as no sender/receiver unit is installed. Assembly and Installation CAUTION: Accident risk When the hole is ready: Gas flows through the pipeline when the ball valve is opened. Keep the ball valve closed and fitted until a sender/receiver unit has been fitted. Secure the ball valve against unintentional activation. Instruct other persons accordingly. Subject to change without notice WARNING: Accident risk As long as a sender/receiver unit is not installed: Gas flows through the pipeline when the ball valve is opened. ▸ Keep the ball valve closed and fitted until a sender/receiver unit has been fitted. ▸ Secure the ball valve against unintentional activation. ▸ Instruct other persons accordingly. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 95 Assembly and Installation Determine path angle and path length Exact values for path angle and length must calculated using the geometric data to keep measuring inaccuracy as low as possible ( Fig. 43, pg. 97, Fig. 44). Enter these values in the device as parameters during start-up pg. 163, § 4.2.2(.). 3.3.1.4 A calculation tool is included in delivery to perform these calculations. Cross-duct versions Path angle for exact nozzle assembly 77.5 ° Fig. 43 Dimension relation for non-retractable sender/receiver units FLSE100-EXS FLSE100-EX, FLSE100-EXRE D2 L NL L 2 D1 a a b k D2 D1 1 Setpoint value for 1 and 2 = 75 ° U-U D1++D2 D2++2 2 S S– –2 2 NL NL -- ---- 0f 8++D1 ---------------------------------------------------------------------------------- atan ---------------------------------------------------------------------------------------==atan a–2d d U S NL D1, D2 a f 96 = = = = = = = b = a – NL – D1 – S cos 1 – NL – D2 – S cos 2 U k = ---- f – NL – D1 – S sin 1 – NL – D2 – S sin 2 L= 2 b +k 2 k = atan --- b Off-center probes distance = 4.9 mm (manufacturer's specification) Pipeline circumference at assembly location Seal thickness = 4 mm Probe nominal length (manufacturer's specification) effective nozzle length ( pg. 93, Fig. 42) Nozzle offset ( pg. 86, § 3.3.1.1) 1 for 1-path measurements, 0.8 for 2-path measurements FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice 22 2 2 UU LL = = a a– –2 2 d d + + -------- +f +D1 D1 + + D2 D2 + + 2 2 S S – – 2 2 NL NL Assembly and Installation Fig. 44 Dimension relation for retractable sender/receiver units FLSE100-EXS L a VL L= D1 VL D2 2 2 U a – 2 d + ---- f + D1 + D2 + 2 VL + 4 S – 2 NL U ---- f + D1 + D2 + 2 VL + 4 S – 2 NL -------------------------------------------------------------------------------------------------------- = atan a – 2 d d U VL S NL a f = = = = = = = Off-center probes distance = 4.9 mm (manufacturer's specification) Pipeline circumference at assembly location Ball valve length Seal thickness = 4 mm Probe nominal length (manufacturer's specification) Nozzle offset ( pg. 86, § 3.3.1.1) 1 for 1-path measurements, 0.8 for 2-path measurement FLSE100-EXRE L D1 2 VL a b Subject to change without notice k VL D2 1 NL b = a – NL – D1 – 2 S – VL cos 1 – NL – D2 – 2 S – VL cos 2 U k = ---- f – NL – D1 – 2 S – VL sin 1 – NL – D2 – 2 S – VL sin 2 L= 2 b +k 2 k = atan --- b FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 97 Assembly and Installation Probe versions Path angle for exact nozzle assembly 75 ° Subject to change without notice Use a suitable protractor to determine and register the actual value. The manufacturer measures the path length for each probe and includes this in the Zero Point protocol in the delivery documents. 98 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation 3.3.2 Installing the meter body (option) in the pipeline The meter body shall be installed in the pipeline in a way that the arrow marking on it corresponds to the flow direction. The flow will be output from the measuring system as a positive value if the sender/receiver units master and slave for cross-duct versions are mounted according to pg. 24, Fig. 2. WARNING: Danger due to size and mass of the meter body The lifting eyes are designed for transporting the meter only. Flange sealing surfaces, nozzles and blank flanges may be damaged when the lifting gear is not attached properly. Do not lift the FLOWSIC100 Flare using these eyes when additional loads (such as blank flanges, filling for pressure tests or piping) are attached ( pg. 83, Fig. 33). If lifting straps are used, wrap them around the meter body. The FLOWSIC100 Flare must not turn over or start to swing while being transported. Take suitable measures to prevent damage to the meter when carrying out any other work (welding, painting) near the FLOWSIC100 Flare. Required installation work Position the FLOWSIC100 Flare at the desired section of the pipeline using the lifting gear. Check for correct seating and alignment of the flange gasket after installing the flange bolts, but prior to tightening. Align the meter body of the FLOWSIC100 Flare such that the offsets between inlet pipe, meter body and outlet pipe are minimized. Insert the remaining fastening bolts and tighten the nuts cross-wise. The tightening torque applied must not be lower than specified in the project planning. Mount the pressure sensing line between pressure tap (option) and pressure transmitter (option). Fill the pipeline and check the installed FLOWSIC100 Flare with meter body and piping connections for leaks. We recommend performing a leak test in accordance with the relevant regulations and standards after completion of the mechanical installation. Subject to change without notice For achieving full measuring range and specified accuracies adhere to the geometric tolerances listed in pg. 86, § 3.3.1. For applications with highest requirements regarding accuracy and measuring range, the meter body may also be delivered by SICK. The manufacturing tolerances are then guaranteed. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 99 Assembly and Installation The internal diameter Di of the pipeline is required for further configuration of the geometric data ( pg. 163, § 4.2.2). It can be calculated as follows: U Di = ---- – 2 W U = Pipeline circumference at assembly location W= Wall thickness We recommend determining the wall thickness by measurement and averaging at 4 positions around the pipe. Suitable ultrasonic measurement techniques can be used for this. The wall thickness data according to ANSI table can deviate from the actual wall thickness by up to 13%. 3.3.3 Installing the MCUP control unit 3.3.3.1 Version without explosion protection and version for Ex zone 2 Install the control unit in a protected location that is easily accessible. Observe the following points during fitting: ● Maintain the ambient temperature according to the Technical Data; take possible radiant heat into consideration (shield if necessary). ● Protect against direct sunlight. ● Whenever possible, choose an assembly location with minimum vibrations; dampen any vibrations if necessary. ● Leave enough clearance for cables and opening the door. ● Select an installation location free of chemical influence (esp. for use in ex zone 2). WARNING: Exposure to some chemicals may degrade the sealing properties of materials used in the following devices: ● Relay (sealed device) type AZ830-2C-12DSE and AZ832-2C-12DSE (manufactured by ZETTLER) assembled on the processor board of the MCU ● Relay (sealed device) type V23092-B1024-A301 (manufactured by SCHRACK) or type FTR-LYRA024Y (manufactured by FUJITSU), assembled in the optional digital output module (SICK part no. 2034659) Used enclosure material (white plastic [glass fiber reinforced PBT]) and encapsulating material (black or white epoxy resin) may degrade particularly in the presence of hydrocarbons and hydrogen sulfide among others. Named components must be inspected periodically (details pg. 197, § 5.2). Using suitable cables, the MCUP control unit can be located up to 1000 m away from the sender/receiver units. We therefore recommend fitting the MCUP in a control room (measuring station or similar) to ensure free access to the MCUP. This considerably simplifies communication with FLOWSIC100 Flare in order to set parameters or to locate malfunction or error causes. It is advantageous to provide weather protection (tin roof or similar), made on-site, for use outdoors. 100 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Extremely ambient temperatures as well as higher concentrations of the chemicals may expedite the degradation. Use long connection cables between the MCUP and the sender/receiver units to install the MCUP in a location with safe conditions. Assembly and Installation Assembly dimensions for MCUP in compact and medium size housing Fig. 45 MCUP assembly dimensions MCUP in compact size housing c b d M8 > 250 a e f Clearance for cables Clearance to open door Measure a b c d e f Dimension in mm MCUP in compact size housing MCUP in medium size housing 160 356 320 242 210 330 340 300 (for ATEX zone 2 version) 320 (for CSA CII Div 2 version) 125 215 > 350 > 550 MCUP in medium size housing b d M8 a > 250 Subject to change without notice c Clearance for cables e f Clearance to open the door FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 101 Assembly and Installation 3.3.3.2 Explosion-protected version for Ex zone 1 Fig. 46 MCUP in Ex housing for zone 1 [all dimensions in mm] E A D A C ØB F Housing variant Size 4 Size 6 A B C D E F 210 312 11 11,5 260 335 445 605 227 281 360 360 Special housing variant - stainless steel Figure 47 MCUP in Ex housing for zone 1 - stainless steel [all dimensions in mm] 470 426 12 Subject to change without notice 275 Ø18 265 550,5 360 176,5 360 150 102 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation 3.3.3.3 Explosion-protected version for CSA Cl I, Div 1 Fig. 48 MCUP in Ex housing for zone CSA Cl I, Div 1[all dimensions in mm] E A A 210 312 B 11 11,5 C 236 335 D 289 410 E 227 281 Subject to change without notice Housing variante Size 4 Size 6 D A C ØB FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 103 Assembly and Installation Installing the MCUP with option "Set fixing plate for 2-inch post" 3. 4 For Control Unit MCUP an optional set for mounting to a 2-inch post is available (not suitable for MCUP compact size or 19“ rack version). Fig. 49 MCUP Ex d fixing plate Detail 1 Detail 2 Detail 2 1 1 2 3 4 2 3 5 4 Round steel bow DIN3570 Washer A13 -A4 Nut M12 -A4 Fixing plate 5 6 7 8 6&7 7 8 Nut M10 DIN934 Spr. washer B10 DIN127 Washer B10,5 DIN125 Screw M10 DIN912 Directions for mounting: Fix plate (4) to post using round steel bow (1), nut (3) and washer (2) Mount MCUP to fixing plate using screw (8), washer (7), washer plus spring washer (7) + (6) and nut (5). 104 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Detail 1 Assembly and Installation 3.5 Installing the sun roof MCUP (option) NOTICE: The sun roof is only to be used to protect the MCUP from direct solar radiation and is not suitable as protection from precipitation. 3.5.1 Sun roof MCUP for wall mounting 3.5.1.1 Components/scope of delivery The sun roof MCUP for wall mounting (Part. No. 2069568) is delivered as a set of the following components. Scope of delivery MCUP for wall mounting Description Part no. Sun roof 4075713 Mounting kit sun roof 2072670 Mounting kit MCUP Size A,B,C,D 2072671 Mounting kit MCUP Size E 2072679 Table 2 Figure 50 Dimensions [mm] 448 447 554 Mounting sun roof MCUP on the wall Use „mounting kit sun roof” on the wall. Use the holes marked in Fig. 51. Figure 51 Mounting sun roof to the wall Subject to change without notice 3.5.1.2 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 105 Assembly and Installation 3.5.1.3 Mounting MCUP on the sun roof The appropriate mounting kit for the mounting of the MCUP on the sun roof can be found in Table 3. Figure 52 Mounting MCUP on the sun roof 1 2 3 4 Subject to change without notice 5 106 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation Table 3 Mounting kits for sun roof MCUP Frame MCUP type MCUP Compact Mounting kit Mounting kit MCUP Size A,B,C,D Orange (1) MCUP Medium Mounting kit MCUP Size A,B,C,D Red (2) MCUP STAHL, Size 4 (with or without terminal compartment) Mounting kit MCUP Size A,B,C,D Subject to change without notice Green (3) FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 107 Assembly and Installation MCUP STAHL size 6 (with or without terminal compartment) Mounting kit MCUP Gr. A,B,C,D Blue (4) MCUP STAHL Stainless Steel 3.5.2 Sun roof MCUP mounting on 2-inch post 3.5.2.1 Components/Scope of delivery The sun roof MCUP for mounting on 2-inch post (Part. No. 2069405) is delivered as a set of the following components: Scope of delivery MCUP for mounting on 2-inch post Description Part No. Sun roof 4075713 Mounting plate 4075714 Mounting kit post bracket 2-inch 2061076 Mounting kit sun roof 2072663 Mounting kit MCUP Size A 2072665 Mounting kit MCUP Size B,C,D 2072666 Mounting kit MCUP Size E 2072664 Table 4 108 Mounting kit MCUP Gr. E FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Black (5) Assembly and Installation Figure 53 Mounting on 2-inch post [all dimensions in mm] 526 447 554 3.5.2.2 Mounting sun roof on 2-inch post Figure 54 Mounting on 2-inch post 2 Subject to change without notice 1 The sun roof for wall mounting is by default delivered with the mounting plate (1) fixed to the inside of the sun roof (2) with the „mounting kit sun roof”. For the mounting on the 2-inch post remove the mounting plate (1) from the sun roof (2). Then fix the mounting plate (1) to the 2-inch post with the „mounting kit post bracket 2-inch”. Finally fix the sun roof (2) on the mounting plate (1) with the “mounting kit sun roof” according to Fig. 55. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 109 Assembly and Installation Figure 55 Mounting on 2-inch post 3.5.2.3 Mounting MCUP on sun roof Subject to change without notice Mount the MCUP to the sun roof as outlined on p. 105, § 3.5. 110 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation 3.6 General notes for installation of sender/receiver units WARNING: ● Observe and follow the valid regulations and safety regulations as well as the safety notices in Section 1. ● Take special precautions for use in plants with increased hazard potential (toxic/aggressive/explosive gases, higher pressure, higher temperature) (risk or serious injuries). ● Use suitable protection measures against possible local hazards or hazards arising from the equipment. ● Observe the permitted operating parameters according to the Figures in pg. 31, § 2.2.1 during all work. Check the following before installing: ● Sender/receiver units to be fitted for a particular measuring point must belong to the same system to ensure the maximum measuring precision possible. Exchanging structurally identical sender/receiver units from different measuring systems is not recommended. Sender/receiver units can only be exchanged against identical units. In this case specific probe parameters must be set using the SOPAS ET program (see Service Manual). ● Sender/receiver units from one system are marked with sequential serial numbers (printed on the device label). The FLSE100 Master always has the lower number and the FLSE100 Slave the higher number. ● Sender/receiver units and nozzles must be compatible ( pg. 54, § 2.2.2). ● Nozzles must be free from weld beads on the inside. NOTICE: The deformation characteristic of the flange gasket has an influence on the geometry of the installation and therefore on the uncertainty of the measurement. SICK recommends: ● Use the same type of gaskets as in original scope of supply only ● Apply a tightening torque of 165 Nm WARNING: Ball valve and sender/receiver unit do not function correctly following incorrect installation. Both parts can be damaged. Serious injuries are possible. Subject to change without notice For installation of seals see instructions of sealing manufacturer in pg. 231, § 6.5. WARNING: Hazards through leaks Operation in leaky condition is not allowed and possibly dangerous. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 111 Assembly and Installation 3.6.1 Installing non-retractable sender/receiver units Non-retractable sender/receiver units can be installed/removed on the nozzles if plant is out of operation only. The gas pipeline must be free of any gas/liquid with hazard potential (toxic or aggressive). Assembly ● Place gasket on the nozzle connection. Consider sealing instructions in chapter 6.5. ● Carefully insert the sender/receiver unit into the nozzle to stop and screw on with fastening screws. ● Check process connection for tightness. 3.6.2 Installing retractable sender/receiver units Retractable sender/receiver units can be installed/removed on the fitting set with observation of the following information while the plant is in operation. WARNING: The gas in the pipeline can be dangerous. Observe and follow the valid regulations and safety regulations as well as the safety notices in Section 1. Take special precautions for use in plants with increased hazard potential (toxic/aggressive/explosive gases, higher pressure, higher temperature) (risk or serious injuries). Use suitable protection measures against possible local hazards or hazards arising from the equipment. Make sure the 2"/3" ball valve (5 in Fig. 56) is closed. Observe the permitted operating parameters according to the Figures in § 2.2.1 during all work. Venting of any gas with hazard potential (toxic, aggressive, explosive etc.) requires always suitable protective measures and safety precautions for safe venting and is in the responsibility of the plant operator ( p. 31, 2.2.1) 112 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice NOTICE: ● Process ball valve 2”/3” (5 in p. 99, Fig. 46) is closing the nozzle and prevents that process gas can escape from the pipeline. ● Process ball valve 2”/3” may be opened only if the sender/receiver unit is mounted tightly. Venting connection must be closed tightly with blind screw. Tightness has to be checked by the user. ● Do not dismount sender/receiver unit as long as process ball valve 2”/3” is not closed tightly. ● Retractable sender/receiver units can be equipped with venting valve (option). Do not open venting valve if process ball valve 2”/3” is opened! ● The process ball valve 2”/3” has a non-symmetric design. The short tube side must be connected to the nozzle, the sender/receiver unit must be connected to the long tube side ( p. 114, Fig. 56) ● Flange gaskets must be replaced at every assembling/disassembling of ball valve and sender/receiver unit. Assembly and Installation Assembly Loosen fastening screws (1) on blind flange (2) and remove the blind flange. Position the sender/receiver unit (3) on the ball valve (4) and screw on with fastening screws (1). Remove cotter pins (6) from guide rods (7) and loosen both fastening nuts (8). Open the ball valve (4). Carefully insert the sender/receiver unit into the ball valve and nozzle to stop and fasten with nut (8). Attach cotter pins (6) to guide rods (7). Check all process connections for tightness. Subject to change without notice Installing the nozzle isolation set To prevent danger of galvanic corrosion a "Nozzle isolation set" can be used (option). For installation see instruction in pg. 231, § 6.5. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 113 Assembly and Installation Fig. 56 Retractable sender/receiver units assembly1 1 2 4 Pipe wall 3 5 6 7 Nozzle 8 7 8 Subject to change without notice 6 1 shown without connection for venting, for device type FLSE100-EXS 114 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation 3.7 Electrical installation 3.7.1 General information, prerequisites All assembly work previously described must be completed (as far as applicable) before starting installation work. Carry out all installation work on-site unless otherwise explicitly agreed with SICK or authorized representatives. This includes laying and connecting the power supply and signal cables, installing switches and mains fuses. WARNING: Electrical Hazards Incorrect cabling can cause device malfunctions, failure of the measurement system or serious injuries. Observe the relevant safety regulations as well as the safety notices in Section 1 during all installation work. Use suitable protection measures against possible local hazards or hazards arising from the equipment. Only connect sender/receiver units to the MCUP control unit as intended. 3.7.2 Cable requirements Subject to change without notice Standard connection cables are part of delivery. Special cables are available on request. ● Cable between s/r units of device type FL100 EX-S Cable type: Exi, coaxial, RG62, connection TNC with safety catch ● Cable between s/r units of device type FL100 EX, EX-RE Cable type: Li2YCYv(TP) 2x2x0,5 mm², with reinforced insulation, from Lappkabel The cable must fulfill the following requirements for function of the device: – Operating capacity < 150 pF/m – Wire cross-sectional area at least 0.5 mm² (AWG20 to AWG16 max.) – Screen with Cu wire mesh ● Cable between s/r units and control unit MCUP Cable type: Li2YCYv(TP) 2x2x0,5 mm², with reinforced insulation, from Lappkabel The cable must fulfill the following requirements for function of the device: – Operating capacity < 150 pF/m – Wire cross-sectional area at least 0.5 mm² (AWG20 to AWG16 max.) – Screen with Cu wire mesh The cable specification above represents the SICK standard cables and does not take into account any special requirements for cabling in hazardous areas. The plant operator is responsible, that all used cables comply with valid regulations and guidelines for cabling in hazardous areas at his plant. Special cables for individual requirements are available on request. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 115 Assembly and Installation Cable glands ● Cable glands for non-ex, ATEX Zone 2 and ATEX Zone 1 are offered by SICK as accessories for the following components: – FLSE100 ATEX Zone 1 without junction box – FLSE100 CSA Cl I, Div1 – MCUP Medium size, non-ex, ATEX Zone 2, CSA Cl I, Div2 – MCUP Ex-d, ATEX Zone 1 ● Cable glands are part of delivery for following components: – FLSE100 ATEX Zone 1 with junction box (cable glands, metric M20, brass, nickel plated or similar) – FLSE100 ATEX Zone 2 with junction box (cable glands, metric M20, brass, nickel plated or similar) – MCUP compact size (cable glands, metric, plastic) NOTICE: Installation of cable glands must be performed in accordance with the cable gland manufacturer‘s operating instructions. NOTICE: Factory pre-installed cable glands at S/R units and MCUP Install only fixed cables and wires in the cable glands. The plant operator must ensure an appropriate strain relief. The cable and conduit entries must be installed with mechanically protection against inadmissible impact energy according to EN 60079-0 section 26.4.2. NOTICE: ● Only analog cable Exi of device type FL100 EX-S is approved for ATEX and CSA versions (interconnection of master and slave unit). ● All other cables offered by SICK are only for ATEX/IECEx versions for use in ATEX zone 1 or zone 2 applications. ● All cable glands offered are only for ATEX/IECEx versions for use in ATEX zone 1 or zone 2 applications. ● Cables, cable glands and other installation material for CSA Cl I, Div 1 versions must be provided by the customer. Solutions for CSA Cl I, Div2/zone 2 versions are available on request. Line length The overall length of all cables must not exceed the following lengths ( pg. 28, § 2.1.3): – 1-path measurement (standard cabling): 1000 m – 2-path or 2x1 path measurement (bus cabling): 500 m – 3x1-path measurement (bus cabling): 300 m 116 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice NOTICE: Suitability of factory pre-installed plastic cable glands at MCUP ATEX Zone 2 In accordance with EN 60079-0, section 26.4.2 the pre-installed PA plastic cable glands at MCUP ATEX zone 2 are suitable for equipment group II with low degree of mechanical hazard (impact energy “low”, tested with drop height 0.4m or 4J). If there is a risk of higher mechanical stress, especially at low temperatures, the use of metal cable glands is recommended (available on request). Assembly and Installation Subject to change without notice Bus cabling This type of cabling is preferable for greater distances between sender/receiver units and control unit. In individual cases it may be possible to terminate the electronics of the sender/receiver unit using a cable termination resistor that is positioned at the end of the bus (no termination in delivery state). Solutions for external terminations are available on request. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 117 Assembly and Installation 3.7.3 Requirements for installation in the Ex zone General requirements WARNING: Explosion Hazard Do not open the enclosures while energized. General ● The documentation for zone classification according to EN/IEC 60079-10 must be available. ● The devices to be used must be checked for suitability for the application area. ● After installation, an initial test of the device and the plant according to EN/IEC 6007917 must be performed. Cabling ● The cables must fulfill the requirements according to EN/IEC 60079-14. ● Cables which are especially endangered by thermal, mechanical or chemical stress, must be protected, e.g. by laying in protective tubes. ● Cables must be flame retardant in accordance with DIN VDE 0472 Part 804 Type of Inspection B / IEC 60332-1 must be demonstrated. ● The cross-section of each individual wire must not be smaller than 0.5 mm². ● Observe the clamping range of the cable glands for cable selection. ● Cables for Ex-e cable glands must comply with the requirements in EN 60079-14 Section 11.3. ● The existing clearance in air and creepage according to EN/IEC 60079-07 or EN/IEC 60079-15 may not be reduced by connection of the cables in the terminal compartments. ● Ex-d cable gland must be suitable for the intended cable type (e.g. cables with or without armoring). ● The cables and conductors for Ex-d cable terminals must comply with the requirements in EN/IEC 60079-14, Section 10.4.2 b). The selection there must be made according to Fig. 1. – If the explosive gas mixture requires an IIC installation and the installation area belongs to zone 1, pressure-proof cable glands and bushings containing seals filled with potting compound must be used for the individual wires, e.g. series 8163/1-PXSS2K for normal, not armored offshore and onshore cables or series 8163/1-PX2K for various armored offshore and onshore cables, both from R.STAHL GmbH. Potting is done on-site. Observe the manufacturer's description. – If the explosive gas mixture requires only an IIB or IIA installation or the installation area belongs to zone 2, suitable pressure-proof cable glands and bushings with a sealing ring can also be used, if the cable is suitable for that. ● Protect the wire ends with connector sleeves against fraying. ● Replace unused cable glands with the enclosed Exe or Ex-d sealing plugs. ● Connect or safeguard unused wires to ground so that a short circuit is excluded with other conductive parts. 118 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Do not connect or disconnect the circuits unless power has been removed or the area is known to be non-hazardous. When using alternative connection of devices not belonging to the system (especially external power supply devices, power supply units, etc.), ensure that the maximum voltage at the connections does not exceed 125 V even if a fault occurs, and that every single cable core is protected separately with a fuse of max. 1 A. Do not use the device if cables or terminals are damaged. Assembly and Installation ● Carry out potential equalization according to EN/IEC 60079-14 (see also the following Section). ● "Conduit" systems must comply with the requirements in EN/IEC 60079-14, Section 9.4 and 9.6. In addition, compliance with national and other relevant standards is required. ● "Conduits" according to IEC 60614-2-1 or IEC 60614-2-5 are not suitable. ● "Conduit" systems must be protected against vibration. ● Use thread sealant according to EN/IEC 60079-14, Section 9.4 for threads with ½" NPT. The following applies additionally for the FLSE100-EXS intrinsically safe cable connection to intrinsically safe ultrasonic transducers/probe: ● The device marking must at least include the information Ex [ib] or Ex [ia]. ● Use only cables delivered by SICK. The connections of the intrinsically safe ultrasonic probes are designed so that the individual circuits are safely separated from other intrinsically safe and non-intrinsically safe circuits. If the transducer circuits are disconnected while energizing, it still must be observed that the safe separation from other intrinsically safe and non-intrinsically safe circuits is not overridden and thus intrinsic safety endangered. For this reason, the associated connection cable should be disconnected at both ends, i.e. unplugged individually and successively, first from the electronics and then, if required, from the ultrasonic probes, or suitably attached to prevent uncontrolled movement of the cable with the unprotected, open cable connector. The cables for the intrinsically safe components are marked either with ”Exi” or a blue cable covering or with blue shrink sleeves on the cable ends or with the SICK item number, at least on the associated packaging. The technical safety data are shown in the Type Examination Certificate. ● Operation of the FLSE100-EXS with sensors not belonging to the system and components and sensors from other manufacturers is not permitted. See the Type Examination Certificate for the technical safety data. See the relevant list in these Operating Instructions for the sensors which may be used with the FLSE100-EXS. Subject to change without notice Specific requirements for installation in USA and Canada ● Installations in USA must be carried out according to NEC (ANSI/NFPa70) ● Installations in Canada must be carried out according to CEC part 1. ● Install sender/receiver units as follows: – FLSE100-EXS and FLSE100-EXPR sender/receiver units according to manufacturing drawing E_41943 in the appendix. – FLSE100-EX and FLSE100-EXRE see manufacturing drawing E_41944 in the appendix. Special requirements for use of MCUP control unit in Cl I, Div 1 Wiring that enters or leaves the system enclosure must utilize wiring methods suitable for Class I, Division 1 Hazardous Locations, as appropriate for the installation. NOTICE: Keep cover tight while circuits are alive. Seal required within 18 inches. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 119 Assembly and Installation Symbol 120 Place Reason Activity not allowed or required Beside the door lock Warning for explosion hazard Do not open while energized. On the fuse Warning for terminal explosion hazard locking The pivoting fuse holder is locked by an additional spring locking device. Do not overstretch this while opening and closing the fuse holder. Using without or with a damaged additional spring locking device is not permitted. Ensure that the fuse holder is locked correctly before using. Do not disconnect unless power supply has been removed or the area is known to be non-hazardous. On the fuse Warning for holder explosion hazard Only replace the fuse with type "sandfilled fuse 2 Amp, 250 V type 522.720, manufactured by ESKA". To prevent repetitive fuse blowing the user shall clarify the causes and shall take appropriate precautionary measures before restarting the equipment. On the internal connectors locking plate Some internal connectors are non selflocking types and must be locked by the additional locking plate against unintentional loosening. Disassemble these connectors before disconnecting and reassemble it after reconnecting. Use without or with a damaged additional locking device is not permitted. Ensure that all internal connectors and optional modules are locked correctly before using. Do not unplug or replug all connectors and subassemblies unless power has been removed or the area is known to be non-hazardous. Do not disconnect unless power has been removed or the area is known to be non-hazardous. Warning for explosion hazard FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Specific requirements for use of MCU-P control unit in zone 2 and CL I, Div2 ● Labelling Assembly and Installation Table 5 Applicable requirements for use in Cl I, Div1 and Cl I, Div2 Applicable requirements for use in Cl I, Div1 and Cl I, Div2 Multi control unit (MCUP) ● CAN/CSA Standard C22.2 No. 0-M91 (Reaffirmed 2006) ● CSA Standard C22.2 No. 94.1-07 (First Edition - September 2007) ● CSA Standard C22.2 No. 94.2-07 (First Edition - September 2007) ● CAN/CSA Standard C22.2 No. 60529:05 ● CAN/CSA-C22.2 No. 61010-1 Second Edition ● CSA Standard C22.2 No. 213-M1987 (Reaffirmed 2008) ● CAN/CSA-C22.2 No. 60079-0:07 ● CAN/CSA-E60079-15:02 ● ANSI/UL Standard 50 (Twelfth Edition, September 2007) ● ANSI/UL Standard 50E (First Edition, September 2007) ● ANSI/IEC 60529-2004 (November 3, 2004) ● ANSI/UL Standard 61010-1-2004 (Second Edition) ● ANSI/ISA-12.12.01-2007 ● ANSI/UL Standard 60079-0 (Fourth Edition, dated August 15, 2005) ● ANSI/UL Standard 60079-15 (First Edition, dated December 2, 2002 with National Differences, Third Edition, dated July 17, 2009) ● CSA Standard C22.2 No 30-M Subject to change without notice Sending / receiving units (FLSE) ● CAN/CSA Standard C22.2 No. 0-M91 (Reaffirmed 2006) ● CSA Standard C22.2 No. 94.1-07 (First Edition - September 2007) ● CSA Standard C22.2 No. 94.2-07 (First Edition - September 2007) ● CAN/CSA Standard C22.2 No. 60529:05 ● CSA Standard C22.2 No. 142-M1987 (Reaffirmed 2000) ● CSA Standard C22.2 No. 30-M1986 (Reaffirmed 2003) ● CSA Standard C22.2 No. 157-92 (Including update No. 2, June, 2003) ● CSA Standard C22.2 No. 213-M1987 (Reaffirmed 2008) ● CAN/CSA-E60079-0:02 ● CAN/CSA-C22.2 No. 60079-1:07 ● CAN/CSA-E60079-11:02 (March 2002) ● CAN/CSA-E60079-15:02 ● ANSI/UL Standard 50 (Twelfth Edition, September 2007) ● ANSI/UL Standard 50E (First Edition, September 2007) ● ANSI/UL Standard 508 (Seventeenth Edition, Dated January 28, 1999. With revisions through and including July 11, 2005.) ● ANSI/UL Standard 1203 (Fourth Edition, September 2006) ● ANSI/UL Standard 913 (Sixth Edition, Dated August 8, 2002. With revisions through and including August 9, 2004) ● ANSI/ISA-12.12.01-2007 ● ANSI/UL 60079-0 (Fourth Edition, dated August 15, 2005) ● ANSI/UL 60079-1-2005 (Fifth Edition, dated August 15, 2005) ● ANSI/UL 60079-11 (Second Edition, dated March 9, 2007) ● ANSI/UL 60079-15 (First Edition, dated December 2, 2002) ● ANSI/ISA 12.27.01-2003 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 121 Assembly and Installation ● Substitutions of components WARNING: Explosion Hazard Substitutions of components may impair suitability for Class I, Division 2 / Zone 2. Replace components only by the original types as follows: ● MCUP Fuse: sand-filled fuse, 2 Amp. rated, type 522.720, manufactured by ESKA (SICK part no. 2054541) Processor board: - Relays, type AZ830-2C-12DSE and AZ832-2C-12DSE, manufactured by ZETTLER - Back up battery, type BR2032, manufactured by PANASONIC ● Optional modules Analog input and output modules as well as digital input modules as listed on p. 230, § 6.3.1. Interface modules ( pg. 230, § 6.3.2): For CSA approved versions only the modules Ethernet + Impulse (SICK part no. 2055719) and Modbus + Impulse (SICK part no. 2048958) may be installed. Subject to change without notice NOTICE: The replacement of parts (relays and other electrical components) soldered on the processor board is not permitted. The information is given purely in order to check whether a complete board to be replaced matches the requirements (details for exchange see Service Manual). 122 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation 3.7.4 Connection of sender/receiver units 3.7.4.1 Terminal assignment in the terminal compartment of FLSE100-EXS/EXPR/EX/EXRE sender/receiver units Fig. 57 Terminal compartment of FLSE100-EXS/EXPR/EX/EXRE sender/receiver unit for zone 2 or for zone 1 Terminal compartment open Terminal compartment cover Ground terminal Connecting diagram (on the inside) Connection of FLSE100-EX/EXRE Master 1 2 3 4 Internal connection * External connection ** Green Yellow Green Yellow Assignment IF1 IF1 IF2 IF2 5 6 7 8 Brown GND White +24 V d.c. Connection of FLSE100-EX/EXRE Slave Internal connection * External connection Assignment 1 2 3 4 Green IF2 Yellow IF2 Green Yellow 5 6 7 Brown GND 8 White +24 V d.c. Connection of FLSE100-EXS/EXPR Subject to change without notice Internal connection * External connection ** Assignment *: **: IF1: IF2: 1 2 3 4 Green IF1 Yellow IF1 Green Yellow 5 6 Brown GND 7 8 White +24 V d.c. Cannot be changed Applicable only for cables with wire color code according to DIN 47100 Communication between FLSE Master and MCUP (interface 1) Communication between FLSE Master and FLSE Slave (interface 2) NOTICE: Self-locking terminals for wire sizes 0.5 .. 2.5 mm² (AWG20 ... AWG12). FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 123 Assembly and Installation 3.7.4.2 Terminal assignment in the Exd terminal compartment of FLSE100-EXS/EXPR/EX/ EXRE sender/receiver units (Ex zone 1 version without Exe terminal compartment) and CSA version Cl I Div1/Div2 Fig. 58 Terminal compartment FLSE100-EXS/EXPR/EX/EXRE sender/receiver unit Master FLSE100 Slave FLSE100 Grounding terminals Terminal compartment open Connection of FLSE100-EX/EXRE Master Designation in terminal compartment B External connection ** Yellow Assignment IF1 Master A +24 V d.c. GND Green White Brown IF1 +24 V d.c. GND B Yellow IF2 Slave A +24 V d.c. GND Green White Brown IF2 +24 V d.c. GND Connection of FLSE100-EX/EXRE Slave Designation in terminal compartment External connection ** Assignment B Yellow IF2 Master A +24 V d.c. GND Green White Brown IF2 +24 V d.c. GND B n.c. Slave A +24 V d.c. n.c. n.c. GND n.c. B n.c. A n.c. Slave +24 V d.c. n.c. GND n.c. Designation in terminal compartment External connection ** Assignment **: IF1: IF2: n.c.: B Yellow IF1 Master A +24 V d.c. GND Green White Brown IF1 +24 V d.c. GND Applicable only for cables with wire color code a.c.cording to DIN 47100 Communication between FLSE Master and MCUP (interface 1) Communication between FLSE Master and FLSE Slave (interface 2) Not connected NOTICE: Self-locking terminals for wire sizes 0.5 .. 1.5 mm² (AWG20 ... AWG16). 124 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Connection of FLSE100-EXS/EXPR Assembly and Installation 3.7.5 MCUP connections 3.7.5.1 MCUP version without explosion protection and for use in zone 2 and Cl I, Div 2 / zone 2 Version in wall housing Fig. 59 MCUP component layout (with options) MCUP compact size housing MCUP medium size housing 1 2 5 5 4 3 6 3 4 DISPLAYMODUL Reset Term BUS - S/E unit 2 com nc. no. com nc. no. com nc. no. com nc. no. com nc. no. relay 3 relay 4 relay 5 relay 1 relay 2 BUS - S/E unit 1 BUS Term 6 1 2 3 7 8 Optional I/O modules Optional interface module Hat rail 5 6 7 2 Fuse T2A Processor board Terminals for power supply Terminals for power supply, screw free 0,5 ...2,5 mm2 (AWG 20 up to AWG 12) Power supply version Voltage rating Wattage rating Terminal no. Marking Function 90 ... 250 V a.c. 1) 90...250 V a.c. max. 50 W 1 L1 Phase conductor 2 N Neutral wire 3 Earth symbol Earthing 1 L1 Phase conductor 2 N Neutral wire 3 Earth symbol Earthing 1 +24 V d.c. plus pole 2 GND minus pole 3 Earth symbol Earthing Subject to change without notice 115/230 V a.c. 2) 24 V d.c. 3) 115/230 V a.c. 24 V d.c. max. 40 W max. 30 W 1): Wide range, not for Div 2 / zone 2 version Automatic switching 3): It may only be used a power supply with safe mains isolation (PELV).The negative terminal is grounded to the housing of device. 2): FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 125 Assembly and Installation NOTICE: ● Screw terminals for wire sizes 0.5 .. 1.5 mm² (AWG20 ... AWG16). ● All cables which are connected to the MCUP must be suitable for a minimum working voltage of 300V. Fig. 60 MCUP processor board connections 8 1 2 9 10 11 3 12 4 13 14 5 7 6 1 2 3 4 5 6 7 RS232 (non-ex MCUP) or RS485 (ex MCUP) Supply voltage 24V d.c. Terminals for analog inputs1 and 2 Terminals for analog output Terminals for digital inputs 1 to 4 Terminals for relays 1 to 5 Terminals for sender/receiver unit master 8 9 10 11 12 13 14 Connection for optional I/O module Backup battery type BR2032 Connection for optional display module Connection for LEDs Connection for optional interface module USB plug Terminals 41, 42 Terminal 1, 2, 3 4, 5, 6 7, 8, 9 10, 11, 12 13, 14, 15 16, 18 17, 18 19, 21 20, 21 22, 23 24 126 Marking on the processor board com, n.c.1), n.o. 2) relay 1 (malfunc.) com, n.c.1), n.o. 2) relay 2 (maint.) com, n.c.1), n.o. 2) relay 3 (check.) com, n.c.1), n.o. 2) relay 4 (maint.requ.) com, n.c.1), n.o. 2) relay 5 (limit) din1, gnd din2, gnd din3, gnd din4, gnd +, gnd Ampere rating Function Voltage rating Indication of malfunction 30 V a.c./d.c. Indication of maintenance Indication of function check Indication of maintenance request Indication of limit violation 1A Digital input 1 (active low forced to gnd) Digital input 2 (active low forced to gnd) Digital input 3 (active low forced to gnd) Digital input 4 (active low forced to gnd) 5.5 V d.c. max. 1 mA Analog output (20 mA) 20 ... 28 V d.c. max. 22 mA Ground FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Terminal data Assembly and Installation Terminal 25, 26 27, 28 29, 30 31, 32 Marking on the processor board ain1, gnd ain2, gnd +, gnd +24, -24 33, 34 35 36, 37 A, B scr. +24, -24 38, 39 40 41, 42 43, 45 A, B scr. +24 -24 extern tx/A, gnd 44, 45 46, 47 48, 49 P1 rx/B, gnd + gnd, 24 V in + gnd, 24 V P1 service Function Analog input 1 Analog input 2 Output 24 V d.c. Power supply bus sender/receiver unit 1 RS485 interface bus sender/receiver unit 1 Screen (gnd) Power supply bus sender/receiver unit 2 RS485 interface bus sender/receiver unit 2 Screen (gnd) Power supply bus sender/receiver units Service interface – RS232 (non-ex MCUP) – RS485 (ex-MCUP, option for non-ex MCUP) Output 24 V d.c. Input 24 V d.c. USB Port Voltage rating max. 3 V d.c. 20 ... 28 V d.c. 20 ... 28 V d.c. ±5V Ampere rating 22 mA 3) max. 100 mA 20 ... 28 V d.c. ±5V max. 100 mA 20 ... 28 V d.c. - 5 V ... +12 V 20 ... 28 V d.c. 20 ... 28 V d.c. 3) 3) 3) 1): normal closed normal open 3): use only according to consultation with the manufacturer Subject to change without notice 2): FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 127 Assembly and Installation Screen connection of control unit MCUP ATEX zone 1 In a limited number of MCUP ATEX zone 1 units shipped, the shield terminal strip is electrically isolated from the housing. In this case the shield terminal strip is mounted on plastic spacers and has no electrical connection to the housing. If in doubt, the isolation can be checked by a electrical continuity test. At affected devices the screen of the connection cable between sender/receiver unit and MCUP can be grounded at MCUP ATEX zone 1 in two ways: 1 Make connection of cable screen at spring-type terminal (1) in the MCUP terminal box. Connect spring-type terminal strip (1) with PE (2) of the MCUP. 2 Make connection of cable screen at spring-type terminal (1) in the MCUP terminal box. Connect spring-type terminal strip with external PE at site. Figure 61 Grounding connection 1 2 Subject to change without notice NOTICE: Grounding of sender/receiver units has to be established according to p. 123, § 3.7.4. The equipotential has to be connected in accordance with IEC 60079-14. 128 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation Version in 19” rack Fig. 62 MCUP connections for 19" variant (without explosion protection) 1 2 3 5 Power supply unit Display module Slot for interface module option 4 5 6 6 I/O module option Terminal connection for power supply 90...250 V AC Terminal connection for wiring by customer Subject to change without notice 1 2 3 4 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 129 Assembly and Installation Terminal data Marking on the processor board com, n.c.1), n.o. 2) relay 1 (malfunc.) com, n.c.1), n.o. 2) relay 2 (maint.) com, n.c.1), n.o. 2) relay 3 (check.) com, n.c.1), n.o. 2) relay 4 (maint.requ.) com, n.c.1), n.o. 2) relay 5 (limit) din1, gnd din2, gnd din3, gnd din4, gnd +, gnd ain1, gnd ain2, gnd +, gnd +24, -24 33, 34 35 36, 37 A, B scr. +24, -24 38, 39 40 41, 42 43, 44 45, 46 47, 48 49, 50 51, 52, 53 54, 56 55,56 57, 60 58, 60 59, 60 71, 73 72, 73 74, 76 75, 76 77, 79 78, 80 A, B scr. 24 V, gnd 24 V, gnd +, 12 V, gnd 5 V, gnd tx/A, rx/B, gnd res 1, gnd res 2, gnd res 3, gnd res 4, gnd res5, gnd A, gnd B, gnd +Us, gnd -Us, gnd imp+, res 1 imp-, res 2 130 Function Indication of malfunction Indication of maintenance Indication of function check Indication of maintenance request Indication of limit violation Digital input 1 (active low forced to gnd) Digital input 2 (active low forced to gnd) Digital input 3 (active low forced to gnd) Digital input 4 (active low forced to gnd) Analog output (20 mA) Ground Analog input 1 Analog input 2 Output 24 V d.c. Power supply bus sender/receiver unit 1 RS485 interface bus sender/receiver unit 1 Screen (gnd) Power supply bus sender/receiver unit 2 RS485 interface bus sender/receiver unit 2 Screen (gnd) Input voltage supply 24V d.c Output voltage supply 24V d.c. Input 30 V electr. isolated Ampere rating Voltage rating 30 V a.c./d.c. 1A 5.5 V d.c. max. 22 V d.c. max. 1 mA max. 24 mA max. 3 V d.c. 22 ... 28 V d.c. 22 ... 28 V d.c. 22 mA 3) ±5V max. 100 mA 22 ... 28 V d.c. ±5V max. 100 mA 22 ... 28 V d.c. - 5 V ... +12 V 4) 4) Internal voltage (not planned for use) 4) RS232/485 4) Reserve (not planned for use) Interface 1 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Terminal 1, 2, 3 4, 5, 6 7, 8, 9 10, 11, 12 13, 14, 15 16, 18 17, 18 19, 21 20, 21 22, 23 24 25, 26 27, 28 29, 30 31, 32 Assembly and Installation Terminal 81, 83 82, 83 84, 86 85, 86 87 88 89 90 P1 Marking on the processor board A, gnd B, gnd +Us, gnd -Us, gnd Function Interface 2 (reserve, not used) Voltage rating Ampere rating Not planned for use P1 service USB Port 2): normal closed normal open 3): Use only according to consultation with the manufacturer Subject to change without notice 1): FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 131 Assembly and Installation 3.7.5.2 MCUP in explosion-protected version for Ex zone 1 and Cl I, Div 1 Fig. 63 MCUP component layout (with options) as explosion-protected version for zone 1 and Cl I, Div 1 Display module (collapsible) Processor board Inside view without processor board Option Interface module Optional I/O module Connection diagrams pg. 242, § 6.7 Cabling Work to be done Connect connection cables according to Fig. 57 ( p. 123) and Fig. 58 ( p. 124) and Fig. 64 ( p. 133) to Fig. 68 ( p. 137). Connect cables for status signals (operation/malfunction, maintenance, check cycle, maintenance requirement, limit value), analog output, analog and digital inputs according to requirements ( pg. 126, Fig. 60). Connect power cable to terminals L1, N, PE ( pg. 125, Fig. 59) Seal cable entries not in use with blind plugs WARNING: Be sure to check the wiring before switching the supply voltage on. Only modify wiring when disconnected from the mains and potential-free. 132 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice 3.7.6 Assembly and Installation Connecting device type FLSE100 EX/EX-RE – S/R units: Ex zone 1 without Exe terminal compartment, CSA CI I, Div1/Div2 – MCUP: without explosion protection, Ex Zone 2 or CSA CI I, Div2 or CSA CI I, Div1 FLOWSIC100 EX/EXRE cabling Connection Interface module Connection display Service RS485* gnd B A MCUP processor board GND a-unit A b-unit A yellow ge E +24 V DC n.o. n.c. n.o. D com n.c. com n.o. n.o. n.c. C white ws brown br green gn B com n.c. Ex zone (Contact position in current-free state) Operation/malfunction Maintenance Check cycle Maintenance request Limit value Slave gnd +24 V DC RS485a RS485b RS485b RS485a +24 V DC gnd Terminal compartment yellow ge green gn white ws brown br FLSE100 Slave brown white green yellow gnd +24 V DC RS485a RS485b Master Note For 2-path, 2x1-path or 3x1-path measurement, the second /third FLSE master and FLSE slave are connected by use of a junction box with Ex certification (available from SICK on request) to the MCUP. ”Point-to-point” wiring for 2-path and 2x1-path measurement on request. brown whitebr ws green gn yellow ge Master FLSE100 Master on-site cabling in explosion protected version according to p. 118, 3.7.3 Subject to change without notice A B C D E Slave n.o. n.c. A com 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 com Safe area (or Ex zone 2 for MCUP in Ex zone 2 or CSA CI I, Div2 or CSA CI I, Div1 Fig. 64 Terminal compartment * MCUP Ex zone 2 only FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 133 Assembly and Installation Connecting FLSE100 EX/EX-RE – S/R units: Ex zone 1 and 2 with Exe terminal compartment – MCUP: without explosion protection, Ex zone 2 FLOWSIC100 EX/EXRE cabling Connection display Service RS485* Connection Interface module gnd B A b-unit A GND a-unit A green gn yellow ge E +24 V DC n.o. n.c. com n.o. n.c. D ws white C com n.o. n.c. n.o. com (Contact position in current-free state) green RS485 a yellow RS485 b green yellow brown gnd brown white +24 V DC white 1 2 3 4 5 6 7 8 Terminal compartment green yellow RS485 a 1 RS485 b 2 3 4 brown gnd 5 6 white +24 V DC 7 8 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Ex zone Note For 2-path, 2x1-path or 3x1-path measurement, the second /third FLSE master and FLSE slave are connected by use of a junction box with Ex certification (available from SICK on request) to the MCUP. ”Point-to-point” wiring for 2-path and 2x1-path measurement on request. 134 Operation/malfunction Maintenance Check cycle Maintenance request Limit value Terminal compartment on-site cabling in explosion protected version according to p. 118, 3.7.3 * MCUP Ex zone 2 only A B C D E FLSE100 Master n.o. n.c. B brown br A com n.c. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 com Safe area (or Ex zone 2 for MCUP in Ex zone 2 version version) MCUP processor board FLSE100 Slave Fig. 65 Assembly and Installation Connecting FLSE100 EX-S/EX-PR – S/R units: Ex zone 1 without Exe terminal compartment, CSA CI I, Div1/Div2 – MCUP: without explosion protection, Ex zone 2 or CSA CI I, Div2 or CSA CI I, Div1 FLOWSIC100 EXS/EXPR cabling gnd B A MCUP processor board b-unit A yellow ge GND a-unit A green gn E +24 V DC n.o. n.c. FLSE100-EXS digital or FLSE100-EXPR Slave gnd +24 V DC RS485a RS485b Master brown br white ws green gn yellow ge Note For 2-path, 2x1-path or 3x1-path measurement, the second /third FLSE master and FLSE slave are connected by use of a junction box with Ex certification (available from SICK on request) to the MCUP. ”Point-to-point” wiring for 2-path and 2x1-path measurement on request. Operation/malfunction Maintenance Check cycle Maintenance request Limit value FLSE100 Master RS485b RS485a +24 V DC gnd ge gn ws br Terminal compartment Connection cable analog to Exi * FLSE100 Slave gnd +24 V DC RS485a RS485b FLSE100-EXS analog * Master Ex zone on-site cabling in explosion protected version according to p. 118, 3.7.3 A B C D E Slave com n.o. n.c. D white ws C com n.o. n.c. n.o. com n.c. n.o. B brown br A com n.c. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 (Contact position in current-free state) Subject to change without notice Connection Interface module Connection display Service RS485** com Safe area (or Ex zone 2 for MCUP in Ex zone 2 or CSA CI I, Div2 or CSA CI I, Div 1) Fig. 66 *: Not for FLSE100-EXPR **: MCUP Ex zone 2 only FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 135 Assembly and Installation Connecting FLSE100 EX-S/EX-PR - S/R units: Ex zone 1 and 2 with Exe terminal compartment - MCUP: without explosion protection, Ex zone 2 FLOWSIC100 EXS/EXPR cabling Connection display Service RS485** Connection Interface module gnd B A A B C D E (Contact position in current-free state) on-site cabling in explosion protected version according to p. 118, 3.7.3 Terminal compartment green yellow Note For 2-path, 2x1-path or 3x1-path measurement, the second /third FLSE master and FLSE slave are connected by use of a junction box with Ex certification (available from SICK on request) to the MCUP. ”Point-to-point” wiring for 2-path and 2x1-path measurement on request. Operation/malfunction Maintenance Check cycle Maintenance request Limit value brown white RS485 a 1 RS485 b 2 3 4 gnd 5 6 +24 V DC 7 8 Connection cable analog to Exi * *: Not for FLSE100-EXPR **: MCUP Ex zone 2 only 136 FLSE100-EXS analog * FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Ex zone b-unit A GND +24 V DC a-unit A yellow ge E n.o. n.c. com n.o. n.c. D white ws C com n.o. n.c. n.o. com com n.c. B brown br green gn A n.o. n.c. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 com Safe area (or Ex zone 2 for MCUP in Ex zone 2 version) MCUP processor board FLSE100-EXS digital or FLSE100 EXPR Fig. 67 Assembly and Installation Bus standard cabling (MCUP without explosion protection version or version for Ex zone 2) - Example for device type FL100 EX-S Fig. 68 Connection of sender/receiver units to the MCUP (bus standard cabling) Connection display Service RS4852 Connection Interface module gnd B A E green D A B C D E yellow C white B A brown Safe area (or Ex zone 2 for MCUP in Ex zone 2 version) MCUP Processor board (Contact position in current-free state) Ex zone Junction box Operation/malfunction Maintenance Check cycle Maintenance request Limit value Cable provided by customer 1) green green green yellow yellow yellow white white white brown brown FLSE100-EXS digital gnd +24 V DC RS485a RS485b Subject to change without notice brown Cable provided by customer to second junction box For Ex zone 2 with optional Exe junction box (on request) For Ex zone 1 only with approved junction box Exi or junction box Exd *: Not for FLSE100-EXPR 2): MCUP Ex zone 2 only **: MCUP Ex zone 2 only Connection cable analog to Exi 1): FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG FLSE100-EXS analog 137 Assembly and Installation 3.7.6.1 Setting the bus address at sender/receiver unit (bus systems only) On bus systems (e.g. 2x1-path connected to one MCUP), the required bus address of a sender/receiver unit (master only) have to be assigned by the software. In delivery condition the bus address for every sender/receiver unit is set by hardware to address "0". Hardware addressing is read in with the start of the SOPAS ET program and cannot be changed at site. NOTICE: ● After a possibly required change of addressing, the respective sender/ receiver units must be started a new (disconnect and reconnect supply voltage). The output assignments in the MCUP then have to be reconfigured (see section 4.2). ● The sender/receiver units must have different addresses. Identical addresses of several units cause the aborting of the communication with the MCUP! 3.7.6.2 Software addressing at sender/receiver units As standard, the address have to be assigned using the SOPAS ET program. The prerequisite for this addressing is that hardware address 0 is set (delivery condition). To change it, do the following: Connect the measuring system to a PC/laptop, start the SOPAS ET program and makecontact with the device (see section 4.1.3). Select the sensor type (e.g. "FL100 EX-S") in the "Scan result" tab and move to the "Project" window. In the "Login" menu, select the "Service" user level and enter password "service" Set the measuring system to the "Maintenance" mode Select the menu "Configuration/Device Parameters" and choose the field "serial interface", set the bus address. WARNING: No other parameters or settings may be changed while logged into access level 2 - "Service", except for those described in this section. All other changes to settings may only be carried out using the access levels 0 - "Operator" or 1 "Authorized client". The manufacturer is not liable for any disruption caused by incorrect settings made by the user in SOPAS. 3.7.7 Fitting and connecting the Interface and I/O module options 3.7.7.1 MCUP in compact or medium size housing Plug interface modules and module carriers for I/O modules onto the hat rail in the MCUP ( pg. 125, Fig. 59) and connect to the associated connection on the processor board with the cable with plug-in connector ( pg. 126, Fig. 60). Then plug the I/O module on the module carrier. Connect I/O modules using the terminals on the module carrier ( Fig. 69, Fig. 70, Fig. 71), the Profibus module using the terminals on the module and connect the Ethernet module via a customer provided network cable. ● Terminal assignment AO module 138 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice For detailed information on the particular module options, see „Interface Documentation FLOWSIC100 Flare“. Assembly and Installation Analog output module terminal assignment Module carrier 14 22 11 1 12 Shield AO1 21 AO2 2 + + 24 AO 2 + - 23 Analog output module 13 Fig. 69 + AO 1 ● Terminal assignment AI module Analog input module terminal assignment (with external power supply) 24 14 23 21 AI 2 11 AI2 AI1 1 + Shield + 2 + - 13 Module carrier 22 Analog input module 12 Fig. 70 + AI 1 WARNING: The analog input module will be damaged if incorrectly connected. Do not connect the terminals 12, 22, 13, 23 of the analog input module to GND or earth if the terminals 11, 21 are connected to the internal supply of the MCUP (delivered configuration) or with another external supply. ● Terminal assignment DO module (2 changeover contacts) Digital output module terminal assignment n.c.^ com. com. n.o. 24 DO2 com. 14 11 DO1 DO2 2 1 Power Relay Digital Outut 21 com. 23 DO1 n.o. 13 Module carrier 22 Digital output module 12 Fig. 71 n.c. Subject to change without notice NOTICE: Screw-fixed terminals for wire sizes 0.5 .. 1.5 mm² (AWG20 ... AWG16). FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 139 Assembly and Installation ● Terminal data Terminal 2x Analog input 11 12 13 14 21 22 23 24 max. voltage max. current AI 1+ AI 1AI 2shield (gnd) AI 2+ AI 1AI 2shield (gnd) 3 V d.c. 22 mA 2x Analog output Module type 2x Digital input Digital output 2 changeover contacts Assignment AO 1+ DI 1+ AO 1gnd AO 2gnd shield (gnd) DI 3+ AO 2+ DI 2+ AO 1gnd AO 2gnd shield (gnd) DI 4+ Rating 15 V d.c. 5.5 V d.c. 22 mA 5 mA n.c. relay 1 com. relay 1 com. relay 2 n.c. relay 2 n.o. relay 1 com. rel. 1 com. rel. 2 n.o. relay 2 30 V a.c./d.c. 2A n.c.: normal closed n.o. normal open ● Terminal assignment interface modules Interface module terminal assignment Interface module Ethernet + Impulse Interface module Modbus + Impulse Interface module HART® Bus – + gnd gnd pulse – + gnd gnd pulse – + gnd gnd pulse not not used used MCU Interface module gnd gnd Fig. 72 Power Tx Rx Impuls HART Subject to change without notice & ImpulsOut part no. : 2050607 + 4..20 mA gal. gnd gnd > 250 Ohm → PLC input 140 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Assembly and Installation Configuration of impulse output: By default the interface modules are set to OC. To change the impulse output to NAMUR a jumper inside the interface module has to be set. Fig. 73 Impulse output NOTICE: Imax (Open collector connection) may not exceed 100 mA. Otherwise the impulse output can be destroyed. Calculate RL according to the equation above. Open collector (default setting) Vc Imax = 100 mA RL NAMUR +8.2 V d.c. 1k 10 k 1k Vc – 2VVc – 2V ------------------- R L --------------------0 1A 0 01A Interface modules mounted on top-hat rail Subject to change without notice Figure 74 0V FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 141 Assembly and Installation Figure 75 19” rack mounted interface module Figure 76 Jumper settings for impulse output Jumper set to OC NAMUR NAMUR OC OC 3.7.7.2 MCUP in 19” rack Plug optional analog and digital modules on the slots in the module carrier beginning with plug-in place 1 in the order AO AI DO DI without gap. If single module types are not available, the next respective one follows according to the order mentioned. Fig. 77 Slots for optional modules Slots for optional I/O modules I/O-MODULE Slot for interface module option INTERFACE-MODULE SICK POWER MULTI CONTROL UNIT FAILURE POWER TxD RxD ERROR MAINTENANCE REQUEST 8 7 6 5 4 3 2 1 Slot 142 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Jumper set to NAMUR Assembly and Installation The MCUP contains 8 slots for optional I/O modules. The connection of these modules (analog and digital types) is carried out at the terminals 101-180. NOTICE: Screw-fixed terminals for wire size 0.5 .. 2.5 mm² (AWG20 ... AWG12). Subject to change without notice Following this, the connection of the modules is represented exemplarily to slot 1. The connection of optional modules (analog and digital type) at the other slots 2-8 is carried out in the same way. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 143 Assembly and Installation ● Connection of analog module Fig. 78 Analog module on slot 1 (terminals 101 - 110) AO (2x) AI (2x) 101 a 101 a 102 b - + 102 b 103 c 103 c 104 d 104 d 105 a 105 a 106 b - + - + + - 106 b 107 c 107 c 108 d 108 d 109 -gnd 109 -gnd 110 scr 110 scr ● Connection of digital module Connection of digital module at plug-in place 1 (terminals 101-110) Signal relays (4x) 144 Power relays (2x) DI (4x) 101 a 101 a 101 a + 102 b 102 b 102 b - 103 c 103 c 103 c - 104 d 104 d 104 d + 105 a 105 a 105 a + 106 b 106 b 106 b - 107 c 107 c 107 c - 108 d 108 d 108 d 109 -gnd 109 -gnd 109 -gnd 110 scr 110 scr 110 scr + FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Fig. 79 Assembly and Installation 3.7.8 Connection of external pressure and temperature transmitters External pressure and temperature transmitters can be connected to the MCUP control unit with loop powering by the MCUP (active transmitters) or external powering (passive transmitters). Default setting of the MCUP is loop powering (wiring diagram ( pg. 256, Fig. 187). Connection – Loop powering by the MCUP Use the internal MCUP backplane PELV power supply, terminals 29 (marked "+24Vdc)" and 30 (marked "gnd"); alternative terminals 46 (marked "+24V") and 47 (marked "gnd") – External powering Use an external power supply specified according to Class2/SELV or PELV; connection according to p. 257, Fig. 188; for installations using the MCUP for zone 1 see wiring diagrams p. 242, Fig. 173 to p. 229, Fig. 167). NOTICE: The analog inputs are damaged by incorrect connection ( pg. 138, § 3.7.7.1, Fig. 70) 3.7.9 Connection of relay contacts All relay contacts must be used in circuits powered by a Class2/SELV or PELV specified power supply only. Two possibilities exist: – Using the internal MCUP backplane PELV power supply Connections: Terminals 46 (marked "+24V") and 47(marked "GND") on the MCUP processor board The additional input wattage caused by additional devices connected to the relay contacts must not exceed 10W. – Using an external power supply specified according to Class2/SELV or PELV. Subject to change without notice NOTICE: ● For MCUP powering the relay contact circuits are connected to earth, which means galvanic isolation is not available. ● Use an external Class2/SELV specified power supply to fulfill isolation from earthing. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 145 Subject to change without notice Assembly and Installation 146 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings FLOWSIC100 Flare 4 Start-up and Parameter Settings Subject to change without notice Basics Standard start-up Advanced start-up Operating/setting parameters via the optional LC-Display FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 147 Start-up and Parameter Settings 4. 1 Basics 4.1.1 General information Start-up primarily comprises entering equipment data (e.g. measuring path, installation angle), parameter settings for output variables and reaction times and, if required, the check cycle setting ( pg. 163, § 4.2.2). A zero adjust is not necessary. An additional velocity measurement calibration using network point measurement with a reference measuring system (e.g. dynamic pressure probe) is necessary only when the velocity profile on the measuring axis is not representative for the overall cross-section. The regression coefficients determined can then be entered into the device without problems ( pg. 190, § 4.3.7). The SOPAS Engineering Tool (SOPAS ET) program is included and serves to set the parameters. The Menu structure simplifies changing settings. Further functions are also available (e.g. data storage, graphic displays). If stable measuring behavior over all equipment states cannot be attained using standard settings (e.g. during device usage at the limits or outside of the specification according to the Technical Data), improvement is possible by optimizing internal device parameters. The required settings may only be made by sufficiently qualified persons due to incorrect settings meaning that the device functionality is no longer ensured. This work should only be carried out by SICK Service. Possible settings are described in the Service Manual. Subject to change without notice We recommend to use the SICK Commissioning check list ( pg. 231, § 6.5) for easy parameter setting. 148 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.1.2 Installing the operating and parameter program SOPAS ET Administrator access rights are required to install the software. Requirements ● Laptop/PC with: – Processor: Pentium III (or comparable type) – VGA graphics card – USB interface (alternative - RS232 via adapter) – Working memory (RAM): At least 1 GB – Operating system: MS Windows XP, Vista, Windows 7 and Windows 8 (32/64 bit) ● USB interface cable to connect the Laptop/PC to the measuring system (MCUP). ● The operating and parameter program (SOPAS ET) as well as the USB driver (scope of delivery) must be installed on the Laptop/PC. ● The power supply must be switched on. Start the file "setup.exe" when the start screen does not appear. Install the SOPAS ET program Insert the delivered CD in the PC drive, select the language, select "Software" and follow the instructions. Install the USB driver A special software driver is required for communication between the operating and parameter program SOPAS ET and the measuring system via the USB interface. To install on the laptop/PC, connect the MCUP to the supply voltage and then connect to the PC using a USB plug-in connector. A message appears on the display that new hardware has been detected. Now load the delivered CD in the PC drive and follow the installation instructions ( pg. 150, Fig. 80). As an alternative, the driver can also be installed in the Windows control panel using the hardware installation program. Subject to change without notice NOTICE: Use only USB cabling which is in scope of SICK supply or cable with identical specification. Maximum cable length is 3 m. Longer cable lengths can lead to communication problems. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 149 Start-up and Parameter Settings Installing the USB driver Subject to change without notice Fig. 80 150 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.1.3 Connecting to the device Connect the USB cable to the MCU control unit ( pg. 125, Fig. ) and the laptop/PC. NOTICE: The MCU(P) is connected via USB to the laptop/PC. A serial interface (COM port) is simulated via which the connection is made. Start the program in the “SICK\SOPAS” start menu. The start page is displayed. 4.1.3.1 Changing the language Subject to change without notice Fig. 81 Changing the language If required, select the desired language in the “Tools / Language” menu ( pg. 151, Fig. 81). Confirm the dialog shown with “Yes” to restart SOPAS ET with the changed language. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 151 Start-up and Parameter Settings 4.1.3.2 Connecting to the device via the “Device family” mode (recommended search settings) 1 Click “Search settings”. 2 Select search mode “Device family oriented search” and click “Next”. Fig. 82 Selecting the search mode 3 Select device family “MCU” and click “Next”. Fig. 83 Selecting the device family NOTICE: MCU(P) does not support automatic recognition of IP addresses (SICK AutoIP), the IP addresses therefore have to be configured manually. Click “Add”. An IP address specified by the customer is entered at the factory if the address is available when the device is ordered. If not, standard address 192.168.0.10 is entered. To change the IP address, see pg. 188, § 4.3.5.2. 152 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice 4 If devices are to be connected via Ethernet, configure the IP addresses: Start-up and Parameter Settings Enter the IP address of the device or the IP address range when several devices are used and confirm with “OK” ( pg. 153, Fig. 84). The IP addresses shown are exemplary. Click “OK”. Fig. 84 Connection settings for connection via Ethernet (example) 5 Click “Next”. 6 When devices are connected via serial connections (COM ports), select the COM ports used and click “Next”. NOTICE: The MCU(P) is connected via USB to the laptop/PC. A serial interface (COM port) is simulated via which the connection is made. If you are not sure which COM ports are used, select all COM ports. Subject to change without notice Fig. 85 Selecting COM ports 7 To save the search settings, enter a name and click “Finish”. SOPAS ET starts the device search. The devices found are displayed in the “Device search” area when device search is finished ( pg. 157, Fig. 92). FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 153 Start-up and Parameter Settings Fig. 86 Saving the scan settings 4.1.3.3 Connecting to the device with advanced mode 1 Click “Search settings”. 2 Select search mode “Interface oriented search”. 3 Select the communication interfaces where the search is to be made and click “Next”. Fig. 87 Selecting the communication components Subject to change without notice 4 Configure the interfaces and click “Next”. 154 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings Ethernet communication Select “Custom IP address configuration”. Click “Add”. Enter the IP address of the device or the IP address range when several devices are used and confirm with “OK”. Select TCP port 2111 in the “TCP port” directory. Define the protocol settings in the “Protocol” directory according to pg. 155, Fig. 88. Fig. 88 Defining the protocol settings Define the timeout settings in the “Timing” directory according to Fig. 89. Defining the timeout settings Subject to change without notice Fig. 89 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 155 Start-up and Parameter Settings Serial communication (when connected via USB) NOTICE: The MCU is connected via USB to the laptop/PC. A serial interface (COM port) is simulated via which the connection is made. Select the COM ports used. If you are not sure which COM ports are used, select all COM ports. Define the baudrate settings in the “Baudrate” directory according to pg. 156, Fig. 90. Fig. 90 Defining the baudrate Configure the data format in the “Format” directory according to pg. 156, Fig. 91. Configuring the data format Define the protocol settings in the “Protocol” directory according to pg. 154, Fig. 87. Define the timeout settings in the “Timing” directory according to pg. 155, Fig. 88. 5 To save the scan settings, enter a name and click “Finish” ( pg. 154, Fig. 86). SOPAS ET starts the device search. The devices found are displayed in the “Device search” area when device search is finished ( pg. 157, Fig. 92). 156 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Fig. 91 Start-up and Parameter Settings 4.1.4 Information on using the program Fig. 92 Overview 3 5 4 6 2 4 Device search abort 5 Device search result 6 Number of devices found Subject to change without notice 1 Device search 2 Project area 3 Device search progress 1 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 157 Start-up and Parameter Settings Device selection Move the required devices with drag-and-drop or a double-click on the required device into the project area. – The configuration of the devices is shown in a separate device window. – The device windows can be opened by a double-click on the respective device file or the context menu ( pg. 159, Fig. 94). Device selection Subject to change without notice Fig. 93 158 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings Fig. 94 Device context menu Table 6 Contents of device context menu Context menu Go online Go offline Connection Upload from device Download to device Login Logout Import Subject to change without notice Export Delete device Description Establishes the connection between SOPAS ET and the device. Interrupts the connection between SOPAS ET and the device. – Select Connection: Changes the connection settings. – Deselect Connection: Deletes the connection settings. Uploads all parameter values from the connected device and transfers them to SOPAS ET. Downloads the parameter values from SOPAS ET to the connected device. Only those parameter values are downloaded which can be written at the currently logged in user level. Opens the login dialog. Logs out the user from the device. Imports a suitable device from the *.sopas file and overwrites the parameter values with the values saved in the *.sopas file. During import to an online device, the parameters are immediately written to the device. Only those parameter values are written which can be written at the currently logged in user level. Exports the device information and the associated project information and saves them in a *.sopas file. Deletes the device from the project. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 159 Start-up and Parameter Settings Password Certain device functions are first accessible after a password has been entered ( pg. 160, § 4.2). Access rights are assigned in 3 levels: User level 0 "Operator" 1 "Authorized Client" 2 "Service" Access to Display measured values and system states Displays, inquiries as well as start-up resp. adjustment to customer-specific demands and diagnosis of necessary parameters Displays, inquiries as well as all parameters required for service tasks (e.g. diagnosis and clearance of possible malfunctions) The Level 1 password is contained in the Annex. Fig. 95 Entering the password 4. 2 Standard start-up This Section describes all the settings essential for device functionality. These include entering equipment data (active measuring path, installation angle) and settings for reaction times, check cycle and standard analog output (calibration settings pg. 190, § 4.3.7). NOTICE: Applications with extremely fluctuating gas compositions In applications with extremely fluctuating gas compositions, it is recommended to optimize the device parameters in cooperation with the manufacturer. Subject to change without notice Error message "Parameter Error" is output when equipment data input is not complete. 160 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.2.1 Entering application-specific parameters in the sender/receiver units Start the SOPAS ET program and connect to the measuring system ( pg. 151, § 4.1.3). Select the required device file (FL100-EX xx) and move it to the project window ( pg. 157, § 4.1.4). The respective connected device type is displayed automatically. Set the sender/receiver units to "Maintenance" mode and enter the Level 1 password ( pg. 157, § 4.1.4). Fig. 96 Setting "Maintenance" mode Select the unit of measurement to be used in the "Tools / Options" menu on the overview page (metric or US standard), pg. 161, § 97. Selecting the unit of measurements Subject to change without notice Fig. 97 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 161 Start-up and Parameter Settings Select the "Configuration / Application Parameter" directory ( pg. 162, Fig. 98) and enter the values determined for path length and angle determined in Section 3.3.1.4 as well as the cross-sectional area. Angle between measuring axis and main gas flow direction (path angle pg. 96, § 3.3.1.4) Path length Distance transducer - transducer (path length L, pg. 96, § 3.3.1.4) Cross-sectional area Internal diameter of the pipeline ( pg. 162, Fig. 98) Configuration / Application Parameters" directory (example for settings) ● The parameters entered are saved in the FLOWSIC100 Flare after the switching from "Maintenance" to "Measurement". ● Set installation parameters are converted automatically when the unit of measurement is changed. ● Enter the calibration coefficient for gas velocity Cv_1 ("Calibration Coefficients" group) as a negative value if FLOWSIC100-EXPR is installed at a vertical pipeline ( pg. 81, § 3.1.3). 162 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Fig. 98 Installation angle Start-up and Parameter Settings 4.2.2 Entering application specific parameters for single-path configuration in the MCUP Select device file "MCU-P" and move it to the "Project " window. Set the MCUP to "Maintenance" mode and enter the Level 1 password ( pg. 157, § 4.1.4). Select the "Parameter / Measure Point 1(2/3) / Measure Point Parameters" directory. Enter the data in the "Measuring Point 1 - Application Parameters (I)" group as listed in the following table. Fig. 99 "Parameter / Measuring Point 1 / Measuring Point Parameters" directory Subject to change without notice Entry field TAG Description Pipe diameter Nominal diameter (inch) Sensor type Adjust factor Low flow cut-off Suppress negative speed Damping time (T90) Parameter Name Name Value Remark TAG No. of the measuring point Description of measuring point Pipe diameter in m Value Select the corresponding value Installation version Select the corresponding type (cross-duct or probe) Has to be determined by a comparision measurement; Value without measurement enter "1" Value Minimum velocity of gas to be suppressed Active Value in s A negative gas velocity is suppressed Response time of measured value at selected measuring point NOTICE: For flow calibrated devices the coefficients CC0 … CC4 must be the same as those detailed on the calibration certificate. If necessary, set the parameters in SOPAS ET with values from the calibration certificate. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 163 Start-up and Parameter Settings 4.2.3 Configuration of application-specific parameters for 10“ pipelines and 2-path configurations In order to set application-specific parameters for 10“ pipelines and 2-path configurations, log into SOPAS via access level 2 - "Service". Establish connection between MCUP and SOPAS ET using USB interface. Log in as "Service" (password "service"). WARNING: No other parameters or settings may be changed while logged into access level 2 - "Service", except for those described in this section. All other changes to settings may only be carried out using the access levels 0 - "Operator" or 1 "Authorized client". The manufacturer is not liable for any disruption caused by incorrect settings made by the user in SOPAS. Fig. 100 Service Login Set SOPAS to maintenance mode. Maintenance mode page Subject to change without notice Fig. 101 164 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.2.3.1 Configuration of SOPAS ET for 10" pipelines 10" pipelines require the following configuration of the linearization parameters. Proceed as follows: Open the "Measuring Point Parameter" page and enter: – Nominal diameter "DN250 / 10 inch" – Sensor type "Cross duct" Fig. 102 Setting the measuring point parameter Subject to change without notice The MCUP will activate the linearization parameter for this selection. SOPAS ET must then synchronize the parameter from the MCUP. To initiate this, perform the following steps: Select menu "Communication"/"Offline" Open the "Measuring Point Parameter" again, and then change back to "online". SOPAS ET will then synchronize the MCUP. To complete the configuration: Open the "Linearization parameter" page. Change parameter cc0 to -223.085 and parameter cc1 to 168.508. Press Enter. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 165 Start-up and Parameter Settings 4.2.3.2 Configuration of application-specific parameters for 2-path configuration The 2-path configuration consists of 2 parallel measurement paths across the secants of the pipeline, significantly reducing the dependency on Reynolds number. To account for this difference, the settings for "Linearization Parameter" and "Adjust factor" must be configured as follows (see SOPAS menu: MCUP Parameter/Measuring point X/Measuring point parameter): Linearization Parameter cc0 = 0 cc1 = 0 cc2 = 1 cc3 = 0 cc4 = 0 Adjust factor: 0.986 2-path configuration settings - Measuring point parameter Subject to change without notice Fig. 103 166 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.2.4 Determining the check cycle Interval time, control value output on the analog output and the starting time-point for automatic check cycles can be modified in the "Adjust / Function Check" directory ("MCU-P" device file). Fig. 104 "Adjust / Function Check" directory (example for settings) Entry field Duration of the check value output Span value Function check interval Start at time of day Parameter Remark Value in seconds Value in % Time between two check cycles Hours Minutes Output duration for control values Determines the span value level pg. 72, § 2.4 pg. 72, § 2.4 Defining a start time-point in hours, minutes and seconds Subject to change without notice The value measured last is output during check value determination. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 167 Start-up and Parameter Settings 4.2.5 Setting the analog outputs parameters Select the "Parameter / I/O Configuration / Analog Output Parameters" directory ("MCU-P" device file") to set the analog outputs. Fig. 105 "Parameter / I/O Configuration / Analog Output Parameters" directory Subject to change without notice The "Analog output 2(3)" fields only appear when an AO module is plugged in. 168 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings Field Error current selection Parameter Yes No Value 1,2 3 or 21 mA Maintenance current selection Basic Parameters Analog Output User value Measuring point Measuring value Live Zero Analog Output 1 User defined value Last Measuring Value Normal measured value output Value- LZ whenever possible Measuring point 1, 2 or 3 Flow a.c. Flow s.c. Mass flow Molar mass Velocity of gas Velocity of sound Zero point (0, 2 or 4 mA) Lower measuring range limit Upper measuring range limit Lower range limit Upper range limit Output check cycle result values On/Off Remark Fault current is output. Fault current is not output. mA value to be output in "Malfunction" state (error case) (size depends on connected evaluation system). The value entered in the "User value" field is output during "Maintenance". The last value measured is output during "Maintenance" The current measured value is output during "Maintenance". mA value to be output in "Maintenance" state Entry field appears only after selection of "Used Defined Value". Volume flow in actual conditions Volume flow in standard conditions The selected measured variables are output on the analog output. Select 2 or 4 mA to ensure being able to differentiate between measured value and switched off device or interrupted current loop. Physical value at live zero Physical value at 20 mA Output of results of check cycle: On No output of results of check cycle: Off Subject to change without notice Set the parameters for fields "Analog output 2(3)" analog to field "Analog output 1". FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 169 Start-up and Parameter Settings 4.2.6 Setting parameters for the pulse output Select the "Parameter / I/O Configuration / Impulse Output" directory ("MCU-P" device file) to set the optionally available pulse output. Fig. 106 "Parameter / I/O Configuration / Impulse Output" directory Field Assigned measuring point Parameter Remark Volume flow in actual conditions Volume flow in standard conditions Measuring value Measuring point 1, 2 or 3 Volume flow a.c. Volume flow s.c. Mass flow Impulse factor Value Test frequency Value Enable test frequency Measuring point 1, 2 or 3 Pulses per m³ or per kg; maximum frequency 10 kHz Input of a value for test purposes to be output at the pulse output If activated, the entered test frequency is output at the pulse output Relation between impulse frequency, volume and impulse factor: [ m³ h ] 3600 •Impulse rating [ 1m³ ] Subject to change without notice Impulse factor [kHz] = Q 170 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.2.7 Setting the analog inputs parameters Select the "Parameter / Measure Point 1(2/3) / Analog Input Parameter" directory ("MCUP" device file) to set the analog inputs. Fig. 107 Field "Parameter / Measuring Point 1 / Analog Input Parameter" directory Parameter External value Constant Value Type of temperature Internal value (S/R value unit A) Type of pressure value External value Constant Value Remark The value of one of the external sensors connected to the analog input is used to calculate the value in standard condition. Selecting the parameter opens entry fields to select the analog input, to set parameters for the physical measured value range and to assign range limits to the analog input limits. A constant value to be entered in the adjacent field is used to calculate the value in standard condition. The temperature value determined internally in sender/receiver unit A is used to calculate the value in standard condition The value of one of the external sensors connected to the analog input is used to calculate the value in standard condition. Selecting the parameter opens entry fields to select the analog input, to set parameters for the physical measured value range and to assign range limits to the analog input limits. A constant value to be entered in the adjacent field is used to calculate the value in standard condition. Subject to change without notice NOTICE: All pressure values in SOPAS are "absolute pressure". FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 171 Start-up and Parameter Settings 4.2.8 Defining the limit value Select the "Parameter / I/O Configuration / Limit Switches" directory ("MCU-P" device file) to set parameters for limit values. "Parameter / I/O Configuration / Limit Switches" directory Field Parameter Assigned Measuring point 1, 2 measuring point or 3 Volume flow a.c. Volume flow s.c. Mass Flow Molar mass Velocity of gas Velocity of sound Temperature Pressure Measured value Density a.c. Absolute Hysteresis type Percentage Hysteresis value Value Limiting value Switching direction 172 Value Over limit Under limit Remark Volume flow in operating state Volume flow in normalized state Gas velocity Speed of sound The limit value settings are assigned to the selected measured variables Assignment of the value entered in the "Hysteresis Value" field as relative or absolute value of defined limit value Defines a tolerance for resetting the limit value relay When value >0, the limit value relay switches when the entered value is exceeded or underflown. Defines the switching direction FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Fig. 108 Start-up and Parameter Settings 4.2.9 Logbook function Subject to change without notice Changes to the device function and in the measuring system are stored in an integrated logbook as event with date and time of recording and resetting. Events recorded: ● Warning measuring point <No.> ● Malfunction measuring point <No.> ● Warning MCUP ● Malfunction MCUP ● Logbook full ● Data archive full ● Measured value limit <No.> exceeded ● Operating mode switched ● Parameter write operation A Maximum of 200 entries are registered in the logbook. A warning is displayed when this limit is reached and the oldest entry is overwritten when exceeded (FIFO principle). The logbook can be deleted. Deletion is noted in the logbook as event "Logbook deleted". Fig. 109 Logbook 4.2.10 Data backup All parameters relevant for recording, processing and input/output of measured values as well as current measured values can be saved and printed. This allows re-entering set device parameters when necessary without problem, or registering device data or states for diagnostic purposes. Data can be saved in the following ways: ● Saving as a project Data recordings can also be stored separately from device parameters. ● Saving as a device file FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 173 Start-up and Parameter Settings Stored parameters can be edited without a connected device and transferred back to the device at a later time. See the Service Manual for a description. ● Saving as a protocol Device data and parameters are registered in the Parameter protocol. A Diagnosis protocol can be created for analysis of the device function and recognition of possible malfunctions. Saving as a project If connections are frequently established, it is advisable to save as a "Project". If connection to the device is to be established again, only this "Project" must be opened. All files previously saved are automatically transferred to SOPAS ET. To save, select the respective device, call up the "Project / Save“ menu and specify target directory and file name. The name of the file to be stored can be chosen freely. It is useful to specify a name with a reference to the measuring point involved (name of the company, equipment designation). "Project / Save" menu Subject to change without notice Fig. 110 174 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings Saving as a protocol Select device, select the "Diagnosis / Protocols" menu and click the button for the desired type of registration. Fig. 111 "Diagnosis / Protocols" menu The file name and storage location must be specified for export to a PDF file. Specifying file names and storage location Subject to change without notice Fig. 112 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 175 Start-up and Parameter Settings Parameter protocol example Fig. 113 FLOWSIC100 Flare Parameter protocol (example) ! "#$$ %& #$$'()$ )6 ., FGE/ ! "#$ &'!( ) &'!( , % **+ ** -,. / ,, ., , 3, 4 3, 4 3, 4 5 6 54 5 6 54 5 6 54 7 6 &9:69 + 0*1 002 ' ' **81 ++*' 5 :;6 5 ,9 > 9 ! 9. 6 , 5 :;6 5 ,9 > 9 ! 9. 6 , 5 :;6+ 5 ,9+ > 9+ ! 9. 6 + >, 69 @->") $ @-%",$ 6 >") $ 6 >") $ 6 !>",$ 6 !%",$ : (: &6C:.9., )9C6::= >.9 ! )6, C6 )6., 5 9,%",$ D,,>") $ D,,%",$ 5. , 69 . D ,9 9 E9= 6 ,9 9 . ,:6 &! ,6C --,9 . 7 9 :,6 :: !7 %69 %699 !9, <#= 8 <#= 8 <#= ? + ? <#= 9 9 0*8A 0*8A A +A B 8B * 0B 9% + +9% +9% 8B B ?0B 9% B *' *1 ' * *08C69 '8'?F0>) 176 .' FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Start-up and Parameter Settings 4.2.11 Starting normal measuring operation Normal measuring operation is started by deactivating the maintenance state (deactivate checkbox in field "Set Operating State"; pg. 160, § 4.2). Standard start-up is now completed. Checking the signal form Checking the signal form allows making a statement on the quality of ultrasonic signals received. Select the FLOWSIC100 Flare type used and then select operating mode "Measurement" in the "Diagnosis / Sensor Values" menu. The ultrasonic signals of both transducers are then displayed in the "Signal Display" field alternating as raw signal and envelope curve. Setting the "View Envelope" function shows the envelope curves of both transducers. The signal patterns should correspond to the displays in Fig. 114 to Fig. 115. Example Burst form HF signal Type FLSE100-EXS (raw signal) Subject to change without notice Fig. 114 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 177 Start-up and Parameter Settings Fig. 115 Burst form demodulated signal Type FLSE100-EXS (envelope curve) Cursor Subject to change without notice Cursors of both transducers must be at same position. 178 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.3 Advanced start-up 4.3.1 Entering customer data Individual customer data can be entered for each measuring point in the "Parameter / Customer Data" directory. To enter, select device file "MCU-P", enter the Level 1 password and set the measuring system to Maintenance mode ( pg. 157, § 4.1.4). "Parameter / Customer Data" directory Subject to change without notice Fig. 116 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 179 Start-up and Parameter Settings 4.3.2 Entering counter function parameters Select device file "MCU-P", enter the Level 1 password and set the measuring system to "Maintenance" mode ( pg. 157, § 4.1.4). Select the "Parameter / Measuring Point 1(2/3) / Measure Point Parameter" directory. Enter values for volume counter resolution and mass counter resolution in the "Measuring point 1 - Counter Parameter" window. When the counter resolution has been changed, reset the counter by clicking "Reset counter". NOTICE: Archives are erased when resetting the counter. Figure 117 "Parameter / Measuring Point 1 / Measuring Point Parameter" directory The current counter level (cumulated) can be viewed in the "Overview Measuring Point 1" directory. 4.3.3 Data archives 4.3.3.1 180 Configuring the data archives The data archives must be configured before being used for the first time. ● Select device file "MCU-P", enter the Level 1 password and set the measuring system to "Maintenance" mode ( pg. 157, § 4.1.4). ● Switch to the "Parameter / Data archives" directory. ● Enter the parameters for recording interval, entry depth, write mode and reference to measuring point for all 9 archives. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Nine (three per measuring point) non-volatile data archives are implemented in the MCUP control unit to create reports according to defined intervals. Start-up and Parameter Settings Figure 118 "Parameter / Data archives" directory Field Gas time Subject to change without notice Interval selection Write mode Measuring point Parameter Remark Defines the daily start-time for writing the archives in order to synchronize the record for multiple Hours, minutes devices 600 entries are made, max. number of entries is set Hourly by the device 30 entries are made, max. number of entries is set Daily by the device 12 entries are made, max. number of entries is set Monthly by the device Free defined Free number of entries (max. 700) and interval „Overwriting mode”:- all stored data will be overwritten if maximum number of entries is Overwriting, stopping reached; „Stopping mode”: data recording is stopped is maximum number of entries is reached Measuring point 1, Select measure point to make the settings for the Measuring point 2, data archive Measuring point 3 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 181 Start-up and Parameter Settings The data archives can be preset individually. An overall maximum number of 5000 entries can be stored over the 9 data archives, 3 archives per measuring point. Clicking "Read data" in the "Diagnosis / Data Archives / Data Archive x" displays the corresponding data archive. The display is not refreshed automatically but must be called up again manually. Clicking "Erase archive" deletes the respective archive in order to start a new recording cycle or to use a different cycle. "Checksum error" is displayed when an error is detected in the data archive. The data archive must then be deleted or formatted to clear the error. Recording stops when "Archive full" is displayed. Fig. 119 "Diagnosis / Data Archives / Data Archive 1" directory Subject to change without notice The retrieved data can be exported as ASCII CSV file. These data can then be used in other applications (e.g. MS Excel). Click "Export data" to export the data and specify the file name and storage location. 182 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings Import of CSV files containing special characters into Excel The correct import of special characters found in the header text of the csv report may require a change to the settings in Excel. To change the settings, perform the following steps in Excel: Open a blank Excel worksheet Select Menu: Data/Import external data/Import data Navigate to the csv file to be imported, click "Open" Select "Delimited" as the original data type Select file origin "65001 : Unicode (UTF-8)", click "Next" Fig. 120 CSV Import settings step 1 (example: Russian header text) Subject to change without notice 4.3.3.2 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 183 Start-up and Parameter Settings Choose the option "Semicolon" as the delimiter, click "Next" Fig. 121 CSV Import settings step 2 Ensure settings are as shown in Fig. 122 and click "Finish" CSV Import settings step 3 Subject to change without notice Fig. 122 184 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings The stored values can be exported in small or large format. Content of file when exporting "Small Format": ● Date & Time ● Counted volume s.c. total [Nm³] ● Counted mass total [kg] ● Gas temperature, average during last recording period [°C] ● Gas pressure, average during last recording period [bar] ● Molar mass [g/mol] ● AGC (Amplifier gain control), average during last recording period ● Performance, average during last recording period ● Meter status Subject to change without notice Content of file when exporting "Large Format": ● Date & Time ● Counted volume a.c. total [m³] ● Counted error volume a.c. total [m³] ● Volume flow a.c., average during last recording period [m³/h] ● Counted volume a.c., collected during last recording period [m³] ● Counted volume s.c. total [Nm³] ● Counted error volume s.c. total [Nm³] ● Volume flow s.c., average during last recording period [Nm³/h] ● Counted volume s.c., collected during last recording period [Nm³] ● Counted mass total [kg] ● Counted error mass total [kg] ● Mass flow, average during last recording period [kg/h] ● Counted mass, collected during last recording period [kg] ● Gas temperature, average during last recording period [°C] ● Gas pressure, average during last recording period [bar] ● Molar mass [g/mol] ● Gas density a.c. [kg/m³] ● AGC (Amplifier gain control), average during last recording period ● Performance, average during last recording period ● Meter status FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 185 Start-up and Parameter Settings 4.3.4 Entering process parameters Further process parameters must be entered to calculate mass flow, molecular weight and gas density. Select device file "MCU-P", enter the Level 1 password and set the measuring system to "Maintenance" mode ( pg. 157, § 4.1.4). Select the "Parameter / Measuring Point 1(2/3) / Process Values" directory. Select the algorithm for measured value computation ( pg. 70, § 2.3.2). If necessary, correct the constant values entered at the factory for the process parameters: – When using the basic algorithm: Viscosity, compressibility, adiabatic coefficient – When using the MR-113-03 algorithm: Gas composition values – When using the Hydrocarbon algorithm: Viscosity, compressibility "Parameter / Measuring Point 1 / Process Values" directory Subject to change without notice Fig. 123 186 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.3.5 Setting Interface module parameters 4.3.5.1 General information The following steps are necessary to select and set the optionally available Interface modules ( pg. 59, § 2.2.4, Optional modules): Select device file "MCU-P", set the measuring system to "Maintenance" mode and enter the Level 1 password ( pg. 157, § 4.1.4). Select the "Parameter / System Configuration“ directory. The Interface module installed is shown under "Interface Module - Type Selection". Configure the Interface module according to requirements. Fig. 124 "Parameter / System Configuration" directory NOTICE: Factory setting for counted flow direction is "positive flow". Subject to change without notice GSD file and measured value assignment are available for the Profibus DP module on request. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 187 Start-up and Parameter Settings 4.3.5.2 Setting Ethernet module parameters Assigning the Ethernet module a new IP address An IP address specified by the customer is entered at the factory if the address is available when the device is ordered. If not, standard address 192.168.0.10 is entered. The following steps are necessary to change the address: Set the desired network configuration in the "Parameter / System Configuration" directory, Field "Interface module Ethernet" field. Click "Reset module" in the "Interface Module - Type Selection". Fig. 125 "Parameter / System Configuration" directory New address Assign the new IP address to SOPAS ET ( pg. 151, § 4.1.3). Subject to change without notice NOTICE: Malfunctions in data transfers not caused by the measuring system can occur during communication via Ethernet. The FLOWSIC100 Flare manufacturer assumes no responsibility for malfunctions that may occur during equipment operation when measured value transfers and their usage to control processes run solely via Ethernet. Increasing the value in the "Scantimeout" field to 3000 ms can minimize communication problems. 188 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.3.6 Setting Modbus and HART® bus module parameters 4.3.6.1 Modbus module Open the "Parameter / System Configuration" directory and select type "RS-485" in the "Select the installed module" menu (group "Interface Module - Type Selection"). Set the protocol type and Modbus address in the "Interface module RS-485" field. Fig. 126 "Parameter / System Configuration" directory A detailed Modbus specification for parameter setting, read-out of measured values and data storage is contained on the product CD belonging to the scope of supply. HART® bus module Open "Parameter / System Configuration" directory and select type "HART" in the "Select the installed module" menu (group "Interface Module - Type Selection"). Fig. 127 "Parameter / System Configuration" directory Subject to change without notice 4.3.6.2 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 189 Start-up and Parameter Settings For operation in HART® bus networks, the polling-address needs a higher value than 0. The modification of the addressing can only be realized via the HART® bus interface itself. Changes of the configuration by using the user software SOPAS ET are not supported. The provided services, commands, telegrams and data types by this module are described in a separate specification. For detailed information, see „Interface Documentation FLOWSIC100 Flare“. 4.3.7 Calibrating gas velocity measurement Subject to change without notice The measuring precision of the velocity measurement can be improved by a comparison measurement with reference measuring system still further. The measured values have to be entered as an offset in the "Adjust factor" window in the "Parameter / Measure Point 1 / Measure Point Parameter" directory, field "Measuring Point 1 - Application Parameter (I)” (. pg. 180, Fig. 117). 190 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Start-up and Parameter Settings 4.4 Operating/setting parameters via the optional LC-Display 4.4.1 General information on use The display and operating interface of the LC-Display contains the functional elements shown in Fig. 128. Fig. 128 LC-Display functional elements Status bar Display field Status LED Current button function Selected menu Control buttons Button functions The function shown depends on the menu currently selected. Only the function shown in the button is available. Button Diag Back Arrow Arrow Subject to change without notice Enter Start Save Meas Function Diagnostic information display (warnings and errors during a start using the Main menu, sensor information during a start using the Diagnostics menu Fig. 129) This function is only active when warnings or malfunctions are present. Switch to higher level menu Scroll up Scroll down Execution of the action selected with an arrow button (switch to a submenu, confirm parameter selected during parameter setting) Start an action Store a changed parameter Toggle between test and graphic display Return from submenu to main menu Display the contrast setting (after 2.5 s) FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 191 Start-up and Parameter Settings 4.4.2 Menu structure Fig. 129 LC-Display menu structure * *: Number depends on available AO‘s/AI‘s 192 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice * Start-up and Parameter Settings 4.4.3 Parameter setting Parameters for inputs/outputs (analog input, output) or device installation (measuring path, installation angle) can be modified as follows: Call the respective submenu, select the line "Limit Low" or "Limit High" and confirm with "Enter". The valid value range is shown in "Min" and "Max". Enter the default password "1234" using the "^" (scrolls from 0 to 9) and/or "" (move the cursor right) buttons. Select the desired value for "Min" or "Max" using the "^" and/or "" and confirm with "Save" The selected value is written to the device. Fig. 130 Menu structure to set parameters AO 1 Parameter 1 Limit Low 2 Limit High 3 Live Zero Limit Low Limit Low 2 Limit High Path Length 2 Installation Angle 3 Cross Section Area /io/para/ao/1/ Save Back Save /io/para/ai/1/ Save Back Save Save Limit Low 6.2 m Min: Max: /sensor/1/para/ /sensor/1/para/ Save Back Subject to change without notice 0.000 Pa Password 1234 Back Min: Max: Limit Low Enter Back Limit Low /io/para/ai/1/ Enter /sensor/1/para/ Back Password 1234 Parameter 1 Back Limit Low /io/para/ai/1/ Back Min: Max: /io/para/ao/1/ Enter AI 1 Parameter 1 0000.00 m³/h Password 1234 /io/para/ao/1 Back Limit Low FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 193 Start-up and Parameter Settings 4.4.4 Using SOPAS ET to modify display settings To modify factory settings, open the "MCU-P" device file, enter the Level 1 password and select the "Parameter / Display Parameter" menu. Fig. 131 "Parameter / Display Parameter" menu Subject to change without notice Entry field Significance Display language Language version shown on the LC-Display Display unit system Unit of measurement system used in displays Assignment of measuring point to first and second measured value bar in the graphic Line 1 to 8 display Value Assignment of measuring variable to the respective measured value bar 194 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Maintenance FLOWSIC100 Flare 5 Maintenance Subject to change without notice General Maintaining the sender/receiver units Maintaining the MCUP for use zone 2 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 195 Maintenance 5. 1 General Maintenance strategy The FLOWSIC100 Flare requires scheduled maintenance just like every electronic measuring system. Regular checks and preventive consumable parts replacement can lengthen the service life considerably and have a decisive influence on measurement reliability. Due to the measuring principle and system design, the FLOWSIC100 Flare only requires a low maintenance effort despite the customary rugged field usage. Maintenance work The work to be carried out is limited to cleaning the sender/receiver units. Switch the FLOWSIC100 Flare to "Maintenance" mode before starting any maintenance work. This can be done using an external maintenance switch (connected to digital input 1), using the SOPAS ET operating and parameter program or via the LC-Display option ( pg. 191, § 4.4). Switch back to "Operation" after completing maintenance work. Maintenance intervals The maintenance interval depends on specific application parameters such as mode of operation, gas composition, gas temperature and moisture as well as the ambient conditions. Typical values are approx. 6 months up to 1 year. Shorter maintenance intervals may be necessary under unfavorable conditions. The plant operator must specify the specific work to be carried out and its performance in a Maintenance Manual. Subject to change without notice Maintenance contract Scheduled maintenance work can be carried out by the plant operator. Only qualified personnel according to Section 1 should be allowed to do the work. If desired, SICK Service or authorized Service support centers can carry out all maintenance work. Any repairs will be made by specialists on-site whenever possible. 196 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Maintenance 5.2 Maintaining the sender/receiver units The sender/receiver units must be cleaned in regular intervals and checked for corrosion and damage. To do this, the sender/receiver units must be dismounted from the nozzles. WARNING: Observe the relevant safety regulations as well as the safety notices in Section 1 during all installation work ( pg. 10, § 1.1 et seq.). Take suitable protection measures against possible hazards. Carry out maintenance work only when hot parts have cooled sufficiently. Required tools and auxiliary means: ● Key for Allen screws SW 5 ● Jaw wrench SW 24 ● Screw driver ● Possibly blind plug for nozzle for non-retractable version ● Brush, cleaning cloth and cleaning alcohol 5.2.1 Removing sender/receiver units Non-retractable sender/receiver units WARNING: At plants with increased hazard potential (toxic, aggressive, explosive gases, health endangering, higher pressure and temperatures), remove the sender/receiver unit only when the plant is out of operation. An amount of gas escapes uncontrolled into the environment during disassembly of the sender/receiver unit from nozzle. Take special precautions in the presence of toxic, aggressive, explosive, hot, or other gases posing a health risk (risk of serious injuries)! Loosen the screws on the flange of the sender/receiver unit. Carefully pull out the sender/receiver unit and place it in a suitable location. Close the nozzle with a blind plug (optionally available). Subject to change without notice Retractable sender/receiver units WARNING: Observe the maximum permitted pressure for operating the retraction mechanism on retractable sender/receiver units: – Device types FLSE100-EXS and EXRE: 16 bar at 50°C ( pg. 42, Fig. 9) – Device type FLSE100-EXPR: 0.5 bar at whole temperature range Close the ball valve after removing the sender/receiver unit with a blind flange. Take special precautions in the presence of toxic, aggressive, explosive, hot, or other gases posing a health risk (risk of serious injuries)! FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 197 Maintenance In principle, the single steps described in § 3.6.2 are carried out in the reverse sequence ( pg. 114, Fig. 56). Loosen fastening nuts (7) and take cotter pins (7) out of guide rods (8). Hold the sender/receiver unit tight and pull it back slowly to stop. Close the 2" (FLSE100-EXS and EXRE) or 3" (FLSE100-EXPR) ball valve (5). A small amount of gas remains in the retractable nozzle and can escape uncontrolled into the environment during disassembly of the sender/receiver unit from the ball valve. Controlled venting is possible when using retractable sender/receiver units with the vent device option (ball valve). To do so, connect the ball valve with a suitable hose that ends away from the measuring point. WARNING: Take special precautions at toxic, aggressive, explosive, health endangering and/or hot gases (risk or serious injuries) when using retractable sender/receiver units without the vent device option. Screw fastening nuts (9) on and insert the cotter pins in the guide rods. Loosen fastening screws (3) and take the sender/receiver unit with seal (6) off the ball valve 2" (or 3"). Fit blind flange (2) and seal on the ball valve 2" (or 3") with fastening screws (1). The delivered seal may only be used once. Replace it with a new one after every disassembly/assembly. 5.2.2 Cleaning the sender/receiver unit Clean the outside of the sender/receiver unit after it has been removed. Inspect the duct probe and transducers for signs of corrosion and replace them if necessary. Dust deposits and caked dust can generally be removed without disassembling the transducer. Depending on the conditions at the installation site, the duct probe and transducers may initially require maintenance more frequently (approx. every 2 weeks or less if necessary). If contamination is limited, the cleaning intervals can be gradually extended to a maximum of 6 months. Reinstall the sender/receiver unit after completion of the work. The work required to replace parts (duct probe, transducers) is listed in the FLOWSIC100 Flare Service Manual. 198 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice WARNING: The transducer must be cleaned with extreme care. Do not damage the transducer diaphragm! Maintenance 5.3 Maintaining the MCUP for use zone 2 Subject to change without notice The relays in the optional relay modules must be inspected periodically. We recommend to begin with short periods of time and to extend depending on the influence strength and the inspection results. To check the relays, open the enclosures of the modules carefully. Suggestions of degradation can be: ● Discoloration ● Deformation ● Perforation ● Malfunction ● Overheating ● Other remarkable changes In the event of any degradation of properties these parts must be replaced by the original type. Replacement by complete processor boards or complete modules is recommended. To prevent repetitive degradation the user shall clarify the causes and shall take appropriate precautionary measures before restart the equipment. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 199 Subject to change without notice Maintenance 200 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications FLOWSIC100 Flare 6 Specifications Subject to change without notice Technical Data Dimensions and Part Numbers Options for MCUP control unit Password Sealing installation instruction Connection diagrams for MCUP Ex zone 1 configuration examples with optional modules Wiring diagrams for USA and Canada FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 201 Specifications Measuring values Measuring range 1) Accuracy 2) 3) Accuracy of molecular weight 3) Technical Data EX-S EX/EX-RE EX-PR Ultrasonic transmit time measurement method Mass flow, standard and actual volumetric flow, molecular weight, totalized standard volume and mass, gas velocity, gas temperature, speed of sound Standard: 0.03 ... ± 120 m/s Standard: 0.03 ... ± 90 m/s 4 1-path measurement: ± 1.5 ... 5.0% / ± 0.5% ) of reading, at range 0.3m/s up to 2-path measurement: ± 1.0 ... 3.0% / ± 0.5% 4) max. value of measuring range < 2% of reading at range 2 ... 120 kg/kmol 1-path measurement: ± 2.5 ... 5.0% of reading, at range 0.3m/s up to Accuracy of mass flow 3) 2-path measurement: ± 2.0 ... 4.0% max. value of measuring range Resolution 0.001 m/s Repeatability 0.2% at 10 m/s Rangeability Max. 4000:1 Max. 3000:1 Internal pipe diameter 5) 4” to 24” 8” to 72” 6) 12” to 72” Measurement conditions ● Standard range: -70 ... +180°C (-95 ... 356 °F) ● High temperature range zone 1: -70 ... +280°C (-95 ... 535 °F) zone 2: -70 ... +260°C (-95 ... 500 °F) Gas temperature 7) ● Low temperature range 8): -196 ... +100°C (-325 ... 210 °F) - 0.5 ... 16 barg Pressure range 0,5 barg for operating the retraction mechanism on retractable version FLOWSIC100 EX-PR Ambient conditions ● Sender/receiver units 9): - 40 ... +70°C (- 40 ... 158 °F); option: - 50 ... +70°C (- 58 ... 158 °F) Temperature range ● MCUP control unit 10): -40 ... +60°C (- 40 ... 140 °F) ;- 20 ... +50 °C (- 4 °F ... 122 °F) for 19” rack ● Sender/receiver units: -40 ... +70°C (-40 ... 158 °F); option: -50 ... +70°C (-58 ... 158 °F) Storage temperature ● MCUP 10): -40 ... +70°C (-40 ... 158 °F) Relative humidity <95% (Use suitable corrosion protection for carbon steel nozzles) Ex approvals Sender/receiver unit, ● ATEX II 1/2 G Ex d [ia] IIC T4 ● ATEX II 2 G Ex d IIC T4 ● ATEX II 1/2 G Ex d [ia] IIC T4 zone 1 ● ATEX II 1/2 G Ex de [ia] IIC T4 ● ATEX II 2 G Ex de IIC T4 ● ATEX II 1/2 G Ex de [ia] IIC T4 ● IECEx Ga/Gb Ex d [ia] IIC T4 ● IECEx Ex d IIC T4 ● IECEx Ga/Gb Ex d [ia] IIC T4 ● CSA Cl I, Div1 Group B, C, D ● CSA Cl I, Div1 Group B, C, D ● CSA Cl I, Div1 Group B, C, D ● CSA Cl I, Div2 Group A, B, C, D ● CSA Cl I, Div2 Group A, B, C, D ● CSA Cl I, Div2 Group A, B, C, D ● CSA Cl I, zone 1/zone 2 IIC T4 ● CSA Cl I, zone 1/zone 2 IIC T4 ● CSA Cl I, zone 1/zone 2 IIC T4 Optional: Optional: Optional: ● Temperature code T6 ● Temperature code T6 ● Temperature code T6 ● Zone 0 for ultrasonic ● Zone 0 for ultrasonic transducers transducers Sender/receiver unit, ● ATEX II 3 G Ex nA IIC T4 Gc zone 2 MCUP control unit, CSA CSA Cl I, Div 1, Groups A, B, C, D; T6; 4X/IP66, enclosure type 4 10) CSA Cl I, Div 2, Groups A, B, C, D; T4; 4X/IP66, enclosure type 4 10) MCUP control unit, zone 1 ATEX II 2 G Ex de IIC T6 MCUP control unit, zone 2 ATEX II 3 G Ex nA II T4 Gc Housing version, degree of protection Sender/receiver units ● For use in zone 1: Flameproof enclosure made of aluminium or stainless steel (option), IP 65/6711) ● For use in zone 2: Housing made of aluminium, IP 65 ● CSA: enclosure type 4, IP65 ● CSA: enclosure type 6, IP 65/ ● CSA: enclosure type 4, IP 65 67 single seal 202 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice 6. 1 Version Measuring parameter Measuring principle Specifications MCUP ● For use in zone 1: Flameproof enclosure made of aluminum, IP 66 ● For use in zone 2, Div2: Wall housing made of steel, IP 66, enclosure type 4 (optionally 4X) ● For use in Div 1: Flameproof enclosure made of aluminum, IP 66, enclosure type 4 (optionally 4X), ● For use in the safe area: Wall housing made of steel, IP 66 and 19” rack made of aluminium, IP 20 Inputs, outputs, controls via MCUP control unit Analog output 1 output active: 0/2/4 ... 22 mA, max. load 500 W, according to NAMUR NE43 Analog inputs 2 inputs: 0 ... 5/10 V or 0 ... 20 mA Digital outputs Pulse/frequency output (opt. module); 5 outputs: : 48 V d.c./1A, 30 V d.c./1A (MCUP zone 2); floating status signals: operation/malfunction, maintenance, check cycle, limit value, maint. request Digital inputs 2 inputs for connection of floating contacts 12) Communication interfaces USB 1.1, RS232 (on terminals) For measured value inquiries and software updates per PC/laptop using the operation program RS485 To connect the sender/receiver units Interface modules Pulse, Ethernet + pulse, Ethernet triplex + pulse, MODBUS TCP + pulse, MODBUS RS485 + pulse, HARTBUS AO + pulse, PROFIBUS RS485 + pulse, Foundation Fieldbus + pulse Power supply Operating voltage ● MCUP non-EX, ATEX zone 1: 100 … 240 V a.c., 50/60 Hz, optional 24 V d.c. ● MCUP ATEX zone 2, CSA Cl I, Div 2: 115/230 V a.c. automatically controlled, optional 24 V d.c. ● MCUP CSA Cl I, Div 1: 100 … 240 V a.c., 50/60 Hz, optional 24 V d.c. Power input Approx. 20 W for all types Fuse protection Fuse T 2 A, slow blow, sand-filled 13) Weight Sender/receiver units Depending on the version, max. approx. 35 kg ● Zone 1 housing size 4: Approx. 14kg ● Zone 1 housing size 6: Approx. 18kg ● Zone 1 housing stainless steel: Approx. 70kg ● Zone 2 and version without explosion protection: Approx. 5 kg ● 19” rack: Approx. 6 kg ● CSA Cl I, Div 1 housing size 4: Approx. 12kg MCUP ● CSA Cl I, Div 1 housing size 6: Approx. 16kg Nozzle ANSI Cl150 2” CS: approx..3,5 kg ANSI CL150 3” CS: approx.. 8 kg Ball valve ANSI CL150 2”: approx..6,1 kg ANSI CL150 3”: approx..12 kg 1): 2): 3): 4): 5): Subject to change without notice 6): 7): 8): 9): 10): Depending on process conditions For fully developed flow profile Hydrocarbons Calibrated, valid at range > 1 m/s ... 120 m/s for types FLOWSIC100 EX-S/EX/EX-RE; > 1 m/s ... 90 m/s for type FLOWSIC100 EX-PR Maximum pipe diameter depending on gas composition Preferred operating range for nominal pipe diameter 24", smaller diameters at difficult gas compositions with soundabsorbing components Operating temperature range of ball valve: standard: -50... +200 °C high temperature: -50 ... +350 °C low temperature: - 196 ... +100 °C On request; use for zone 1 only FLOWSIC100 EX-S and FLOWSIC100 EX-PR Sender/receiver units with ex group IIC T6: - 40 ... +55 °C (- 40 ... 131 °F); option: - 50 ... +55 °C (- 58 ... 131 °F); IIC T6 not for gas temperature > 80 °C For some device configurations the temperature range is reduced. The permitted temperature range is indicated on the device label. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 203 Specifications MCUP Zone 1, Aluminium housing: -40 ... +55 °C ( -40 ... +131 °F) - ATEX / IECEx -55 ... +55°C ( -67 ... +131°F) für 24V DC - ATEX / IECEx on request MCUP Zone 1, stainless steel housing: -20 ... +40 °C ( -4 ... +104 °F) - ATEX -20 ... +40 °C ( -4 ... +104 °F) - IECEx -20 ... +55 °C ( -4 ... +131 °F) - ATEX on request MCUP Div 2, -40 ... +60°C (-40 ... +140 °F) - Group A, B, C, D T4 MCUP Div 1, -25 ... +50°C (-13 ... +122 °F) - Group A, B, C, D -50 ... +50°C (-58 ... +122 °F) - Group C, D 11): IP67 for sender/receiver units without junction box only. Additional inputs/outputs when using optional modules. 13): Replacement fuses T 2 A are part of delivery. Ex-protected control units contain a separate note on label of the fuse type. Subject to change without notice 12): 204 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications Dimensions and Part Numbers 6.2 The devices of the FLOWSIC100 Flare measuring system adhere at least the limits of the EMC guideline class A . The requirements on the disturbing radiation in residential areas weren't taken into account in the approval. All measurements specified are in millimeters. FLOWSIC100 EX-S sender/receiver units1 6.2.1 Sender/receiver units FLSE100-EXS according to ATEX for Ex Zone 2 only, nonretractable2 Fig. 132 Sender/receiver unit FLSE100-EXS Master A A -A 120 48 A 55.5 Fig. 133 60 155.5 Ø 120.7 Ø 150 150 Sender/receiver unit FLSE100-EXS Slave A A -A 48 A 150 Ø 120.7 Ø 150 Subject to change without notice 171.5 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 2" CL150 RF acc. to ASME B16.5. DN50 PN16 form B1 acc. to EN 1092-1 available as option FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 205 Specifications Sender/receiver units FLSE100-EXS according to ATEX for Ex zone 1/zone 2, nonretractable1, 2 Fig. 134 Sender/receiver unit FLSE100-EXS Master A 120 A -A 48 A 56.5 Fig. 135 103 155.5 Ø 120.7 Ø 150 150 Sender/receiver unit FLSE100-EXS Slave A -A A 48 A 150 Ø 120.7 Ø 150 Subject to change without notice 171.5 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 2" CL150 RF acc. to ASME B16.5. DN50 PN16 form B1 acc. to EN 1092-1 available as option 206 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications Sender/receiver units FLSE100-EXS according to ATEX for Ex Zone 1/zone 2, IECEx zone 1 and according to CSA for Cl I, Div.1/Div.2, non-retractable1, 2 Fig. 136 Sender/receiver unit FLSE100-EXS Master A A -A 163 48 A 95.5 Fig. 137 155.5 Ø 120.7 Ø 150 148 Sender/receiver unit FLSE100-EXS Slave A -A A 48 A 150 Ø 120.7 Ø 150 Subject to change without notice 171.5 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 2" CL150 RF acc. to ASME B16.5. DN50 PN16 form B1 acc. to EN 1092-1 available as option FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 207 Specifications Sender/receiver units FLSE100-EXS according to ATEX for Ex zone 2 only , retractable1, 2 Fig. 138 Sender/receiver unit FLSE100-EXS Master A 120 A 48 56.5 Fig. 139 60 172 Ø 120.7 Ø 165 332 Sender/receiver unit FLSE100-EXS Slave A 48 332 Ø 120.7 Ø 165 NOTICE: High temperature version has different design of retraction flange with longer total lengths of +111mm. 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 2" CL150 RF acc. to ASME B16.5. DN50 PN16 form B1 acc. to EN 1092-1 available as option 208 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice 188 Specifications Sender/receiver units FLSE100-EXS according to ATEX for Ex zone 1/ zone 2, retractable1, 2 Fig. 140 Sender/receiver unit FLSE100-EXS Master A -A 163 A 48 A 56.5 Fig. 141 103 172 Ø 120.7 Ø 165 332 Sender/receiver unit FLSE100-EXS Slave A A 48 Subject to change without notice 188 332 Ø 120.7 Ø 165 NOTICE: High temperature version has different design of retraction flange with longer total lengths of +111mm. 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 2" CL150 RF acc. to ASME B16.5. DN50 PN16 form B1 acc. to EN 1092-1 available as option FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 209 Specifications Sender/receiver units FLSE100-EXS according to ATEX for Ex Zone 1/zone 2, IECEx zone 1 and according to CSA for Cl I, Div.1/Div.2, retractable1, 2 Fig. 142 Sender/receiver unit FLSE100-EXS Master A A 163 48 93 Fig. 143 172 Ø 120.7 Ø 165 332 Sender/receiver unit FLSE100-EXS Slave A A 48 332 Ø 120.7 Ø 165 NOTICE: High temperature version has different design of retraction flange with longer total lengths of +111mm. 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 2" CL150 RF acc. to ASME B16.5. DN50 PN16 form B1 acc. to EN 1092-1 available as option 210 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice 188 Specifications 6.2.2 FLOWSIC100 EX/EX-RE sender/receiver units Sender/receiver units FLSE100-EX according to ATEX for Ex Zone 2 only, non-retractable1, 2 Fig. 144 Sender/receiver unit FLSE100-EX A -A 120 A 45 A 55.5 60 155.5 Ø 120.7 Ø 150 198 Sender/receiver units FLSE100-EX according to ATEX for Ex Zone 1/ zone 2, nonretractable1, 2 Fig. 145 Sender/receiver unit FLSE100-EX A -A 163 A 45 A 103 155.5 198 Ø 120.7 Ø 150 Subject to change without notice 56.5 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 2" CL150 RF acc. to ASME B16.5. DN50 PN16 form B1 acc. to EN 1092-1 available as option FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 211 Specifications Sender/receiver unit FLSE100-EX according to ATEX for Ex Zone 1/zone 2, IECEx zone 1 and according to CSA for Cl I, Div.1/Div.2, non-retractable1, 2 Fig. 146 Sender/receiver unit FLSE100-EX A 163 A 45 A 93 155.5 Ø 120.7 Ø 150 198 Sender/receiver units FLSE100-EXRE according to ATEX for Ex Zone 2 only, retractable1, 2 Fig. 147 Sender/receiver unit FLSE100-EXRE A 120 A 45 55,5 60 152 131.5 380 Ø 120.7 Subject to change without notice Ø 152.4 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 2" CL150 RF acc. to ASME B16.5. DN50 PN16 form B1 acc. to EN 1092-1 available as option 212 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications Sender/receiver units FLSE100-EXRE according to ATEX for Ex zone 1/zone 2, retractable1, 2 Fig. 148 Sender/receiver unit FLSE100-EXRE A 163 A 45 56,5 103 152 131.5 380 Ø 120.7 Ø 152.4 Sender/receiver units FLSE100-EXRE according to ATEX for Ex Zone 1/zone 2, IECEx zone 1 and according to CSA for Cl I, Div.1/Div.2, retractable1, 2 Fig. 149 Sender/receiver unit FLSE100-EXRE A A 163 45 93 152 131.5 380 Ø 120.7 Subject to change without notice Ø 152.4 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 2" CL150 RF acc. to ASME B16.5. DN50 PN16 form B1 acc. to EN 1092-1 available as option FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 213 Specifications FLOWSIC100 EX-PR sender/receiver units 6.2.3 Sender/receiver units FLSE100-EXPR according to ATEX for Ex zone 2 only, nonretractable1, 2 Fig. 150 Sender/receiver unit FLSE100-EXPR A -A Ø 190 Ø 152.4 120 A 65 A 55.5 60 158 220 297 Sender/receiver units FLSE100-EXPR according to ATEX for Ex zone 1/zone 2, nonretractable1, 2 Fig. 151 Sender/receiver unit FLSE100-EXPR A -A Ø 190 Ø 152.4 163 A 65 A 103 158 220 297 Subject to change without notice 56.5 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 3" CL150 RF acc. to ASME B16.5. DN80 PN16 form B1 acc. to EN 1092-1 available as option 214 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications Sender/receiver units FLSE100-EXPR according to ATEX for Ex Zone 1/zone 2, IECEx zone 1 and according to CSA for Cl I, Div.1/Div.2, non-retractable1, 2 Fig. 152 Sender/receiver unit FLSE100-EXPR A -A 163 A Ø 190 Ø 152.4 65 A 93 158 220 297 Sender/receiver units FLSE100-EXPR according to ATEX for Ex zone 2 only, retractable1, 2 Fig. 153 Sender/receiver unit FLSE100-EXPR A-A 120 A 65 A 55.5 60 158 342 400 297 Ø 152.4 Subject to change without notice Ø 190 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 3" CL150 RF acc. to ASME B16.5. DN80 PN16 form B1 acc. to EN 1092-1 available as option FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 215 Specifications Sender/receiver units FLSE100-EXPR according to ATEX for Ex zone 1/zone 2, retractable1, 2 Fig. 154 Sender/receiver unit FLSE100-EXPR A-A A 163 65 A 56.5 103 158 342 400 297 Ø 152.4 Ø 190 Sender/receiver units FLSE100-EXPR according to ATEX for Ex Zone 1/zone 2, IECEx zone 1 and according to CSA for Cl I, Div.1/Div.2, retractable1, 2 Fig. 155 Sender/receiver unit FLSE100-EXPR A-A A 163 65 A 93 158 342 400 297 Ø 152.4 Subject to change without notice Ø 190 1 For part nos. see p. 217, 6.2.4 2 Process connections to fit flange 3" CL150 RF acc. to ASME B16.5. DN80 PN16 form B1 acc. to EN 1092-1 available as option 216 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications 6.2.4 Sender/receiver units - parts list Table 7 FLOWSIC100 EX-S non-retractable Sender/receiver Unit Sensor system ATEX Zone 1/IECEx, stainless steel FLSE100-EXS 148SA218VS NN 81CDAMN NN FLSE100-EXS 148SA218VS NN N1CNNNN NN Sensor system ATEX Zone 2 with junction box, stainless steel FLSE100-EXS 148SA218VS NN 82CSAMY NN FLSE100-EXS 148SA218VS NN 82CSAMY NN Sensor system CSA CI I, Div1/Div2, stainless steel FLSE100-EXS 148SA218VS NN 83CDATN NN FLSE100-EXS 148SA218VS NN N3CNNNN NN Sensor system ATEX Zone 1/IECEx, titanium FLSE100-EXS 148TA218VS NN 81CDAMN NN FLSE100-EXS 148TA218VS NN N1CNNNN NN Sensor system ATEX Zone 2 with junction box, titanium FLSE100-EXS 148TA218VS NN 82CSAMY NN FLSE100-EXS 148TA218VS NN N1CNNNN NN Sensor system CSA CI I, Div1, titanium FLSE100-EXS 148TA218VS NN 83CDATN NN FLSE100-EXS 148TA218VS NN N3CNNNN NN Subject to change without notice Table 8 Part No. 1057382 1047661 1046287 1046356 1047667 1047668 1057408 1047664 1047656 1047657 1047671 1047672 FLOWSIC100 EX-S retractable Sender/receiver Unit Sensor system ATEX Zone 1/IECEx, stainless steel FLSE100-EXS 330SA218VS RS 81CDAMN NN FLSE100-EXS 330SA218VS RS N1CNNNN NN Sensor system ATEX Zone 2 with junction box, stainless steel FLSE100-EXS 330SA218VS RS 82CSAMY NN FLSE100-EXS 330SA218VS RS N2CNNNN NN Sensor system CSA CI I, Div1, stainless steel FLSE100-EXS 330SA218VS RS 83CDATNNN FLSE100-EXS 330SA218VS RS N3CNNNN NN Sensor system ATEX Zone 1/IECEx, titanium FLSE100-EXS 330TA218VS RS 81CDAMN NN FLSE100-EXS 330TA218VS RS N1CNNNN NN Sensor system ATEX Zone 2 with junction box, titanium FLSE100-EXS 330TA218VS RS 82CSAMY NN FLSE100-EXS 330TA218VS RS N2CNNNN NN Sensor system CSA CI I, Div1/Div2, titanium FLSE100-EXS 330TA218VS RS 83CDATN NN FLSE100-EXS 330TA218VS RS N3CNNNN NN FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Part No. 1057409 1047662 1047655 1046268 1047669 1047670 1057411 1047666 1047659 1047660 1047673 1047674 217 Specifications Table 9 FLOWSIC100 EX non-retractable Sender/receiver Unit Sensor system ATEX Zone 1 with junction box, stainless steel FLSE100-EX 198SA214VS NN 41CDAMN NN Sensor system ATEX Zone 2 with junction box, stainless steel FLSE100-EX 198SA214VS NN 42CSAMY NN Sensor system CSA CI I, Div1/Div2, stainless steel FLSE100-EX 198SA214VS NN 43CDATN NN Sensor system ATEX Zone 1/IECEx, titanium FLSE100-EX 198TA214VS NN 41CDAMN Sensor system ATEX Zone 2 with junction box, titanium FLSE100-EX 198TA214VS NN 42CSAMY NN Sensor system CSA CI I, Div1/Div2, titanium FLSE100-EX 198TA214VS NN 43CDATN NN Table 10 Part No. 1057412 1047693 1047697 1057413 1047695 1047699 FLOWSIC100 EX-RE (retractable) Part No. 1057414 1047694 1047698 1057415 1047696 1047700 Subject to change without notice Sender/receiver Unit Sensor system ATEX Zone 1/IECEx, stainless steel FLSE100-EXRE 380SA214VS RS 41CDAMN NN Sensor system ATEX Zone 2 with junction box, stainless steel FLSE100-EXRE 380SA214VS RS 42CSAMY NN Sensor system CSA CI I, Div1/Div2, stainless steel FLSE100-EXRE 380SA214VS RS 43CDATN NN Sensor system ATEX Zone 1/IECEx, titanium FLSE100-EXRE 380TA214VS RS 41CDAMN NN Sensor system ATEX Zone 2 with junction box, titanium FLSE100-EXRE 380TA214VS RS 42CSAMY NN Sensor system CSA CI I, Div1/Div2, titanium FLSE100-EXRE 380TA214VS RS 43CDATN NN 218 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications Table 11 FLOWSIC100 EX-PR non-retractable Sender/receiver Unit Sensor system ATEX Zone 1/IECEx, titanium FLSE100-EXPR 220TA311VS NN 11CDAMN NN Sensor system ATEX Zone 2 with junction box, titanium FLSE100-EXPR 220TA311VS NN 12CSAMY NN Sensor system CSA CI I, Div1/Div2, titanium FLSE100-EXPR 220TA311VS NN 13CDATN NN Table 12 Part No. 1057416 1047683 1047687 FLOWSIC100 EX-PR retractable Part No. 1057417 1047684 1047688 Subject to change without notice Sender/receiver Unit Sensor system ATEX Zone 1/IECEx, titanium FLSE100-EXPR 400TA311VS RS 11CDAMN NN Sensor system ATEX Zone 2 with junction box, titanium FLSE100-EXPR 400TA311VS RS 12CSAMY NN Sensor system CSA CI I, Div1/Div2, titanium FLSE100-EXPR 400TA311VS RS 13CDATN NN FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 219 Specifications 6.2.5 Connection cables 6.2.5.1 Non-armored connection cables (SICK standard for ATEX installations) Connection between s/r units or s/r unit master and junction box Designation Part No. FLOWSIC100-EXS Connection cable, analog, Exi, TNC - TNC 3 m 20506141 FLOWSIC100 EX/EXRE Connection cable, 5 meter, for FLSE100 with Exe junction box, tinned leads 2052424 Connection cable, meter good, for FLSE100 with Exe junction box, single wires 7041941 1 Intrinsically safe connection, also suitable for CSA installations Connection between s/r unit master and MCUP Designation Part No. Connection cable, 5 meter, for FLSE100 with Exe junction box, tinned leads 2055381 Connection cable, 10 meter, for FLSE100 with Exe junction box, tinned leads 2055386 Connection cable, meter good, for FLSE100 with Exe junction box, single wires 7041941 6.2.5.2 Armored connection cables (SICK standard for ATEX installations) Connection between s/r units or s/r unit master and junction box Designation Part No. FLOWSIC100-EXS Connection cable FLSE / FLSE analog,armoured, Exi, TNC/TNC, 3 meter,with 2075210 safety catch,for FLSE100 EX-S FLOWSIC100 EX/EXRE Connection cable, armored, XLPE (high temp., halogen free), meter good 6042293 Connection between s/r unit master and MCUP Designation Connection cable, armored, XLPE (high temp., halogen free), meter good 6.2.5.3 Part No. 6042293 Cable glands for non-armored cable types (SICK standard for ATEX installations) Designation Ex-d cable gland metric, M20 brass Ex-d cable gland metric M20, stainless steel Ex-d cable gland NPT 1/2", brass Ex-d cable gland NPT 1/2", stainless steel 220 Part No. 5324884 5324992 5324915 5325257 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Sender/receiver units Specifications Control unit MCUP Designation Exe cable gland metric M20, brass Exe cable gland metric M20, stainless steel Exe cable gland metric M25, brass Exe cable gland metric M25, stainless steel Exe cable gland NPT 1/2", brass Exe cable gland NPT 1/2", stainless steel Exe cable gland NPT 3/4", brass Exe cable gland NPT 3/4", stainless steel 6.2.5.4 Part No. 5321687 5325259 5325260 5325261 5325262 5325263 5325264 5325265 Cable glands for armored cable types (SICK standard for ATEX installations) Sender/receiver units Designation Ex-d cable gland metric M20, brass Ex-d cable gland metric M20, stainless steel Ex-d cable gland NPT 1/2", brass Ex-d cable gland NPT 1/2", stainless steel Part No. 5324271 5325258 5324801 5324296 Control unit MCUP Part No. 5325266 5325267 5325268 5325270 5325271 5325272 5325273 5325274 Subject to change without notice Designation Exe cable gland metric M20, brass Exe cable gland metric M20, stainless steel Exe cable gland metric M25, brass Exe cable gland metric M25, stainless steel Exe cable gland NPT 1/2", brass Exe cable gland NPT 1/2", stainless steel Exe cable gland NPT 3/4", brass Exe cable gland NPT 3/4", stainless steel FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 221 Specifications 6.2.6 Junction box for Ex zone 2 (for ATEX versions only) In Aluminium housing 52 Junction box Mounting holes 80 Fig. 156 113 57 125 Ground terminal 10 Ø 4.8 Part No. 2046562 2031890 Subject to change without notice Designation Junction box for connection cable for zone 2 Fastening set 2D4-1.4571/PA (for junction box for connection cable) 222 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications 6.2.7 Nozzles Nozzle 2" for FLSE100-EXS, carbon steel, nozzle type Long Welding Neck Designation Nozzle CL1502Z, prepared for pipe size 4" Nozzle CL1502Z, prepared for pipe size 6" Nozzle CL1502Z, prepared for pipe size 8" Nozzle CL1502Z, prepared for pipe size 10" Nozzle CL1502Z, prepared for pipe size 12" Nozzle CL1502Z, prepared for pipe size 14" Nozzle CL1502Z, prepared for pipe size 16" Nozzle CL1502Z, prepared for pipe size 18" Nozzle CL1502Z, prepared for pipe size 20" Nozzle CL1502Z, prepared for pipe size 22" Nozzle CL1502Z, prepared for pipe size 24" Part No. 2055388 2055391 2054627 2055392 2051965 2052154 2052155 2052156 2052157 2052158 2052159 Subject to change without notice Nozzle 2" for FLSE100-EX and EX-RE, carbon steel, nozzle type Long Welding Neck Designation Nozzle CL1502Z, prepared for pipe size 8" Nozzle CL1502Z, prepared for pipe size 10" Nozzle CL1502Z, prepared for pipe size 12" Nozzle CL1502Z, prepared for pipe size 14" Nozzle CL1502Z, prepared for pipe size 16" Nozzle CL1502Z, prepared for pipe size 18" Nozzle CL1502Z, prepared for pipe size 20" Nozzle CL1502Z, prepared for pipe size 22" Nozzle CL1502Z, prepared for pipe size 24" Nozzle CL1502Z, prepared for pipe size 26" Nozzle CL1502Z, prepared for pipe size 28" Nozzle CL1502Z, prepared for pipe size 30" Nozzle CL1502Z, prepared for pipe size 32" Nozzle CL1502Z, prepared for pipe size 34" Nozzle CL1502Z, prepared for pipe size 36" Nozzle CL1502Z, prepared for pipe size 38" Nozzle CL1502Z, prepared for pipe size 40" Nozzle CL1502Z, prepared for pipe size 42" Nozzle CL1502Z, prepared for pipe size 44" Nozzle CL1502Z, prepared for pipe size 46" Nozzle CL1502Z, prepared for pipe size 48" Nozzle CL1502Z, prepared for pipe size 52" Nozzle CL1502Z, prepared for pipe size 56" Nozzle CL1502Z, prepared for pipe size 60" Nozzle CL1502Z, prepared for pipe size 64" Nozzle CL1502Z, prepared for pipe size 68" Nozzle CL1502Z, prepared for pipe size 72" FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Part No. 2055395 2055396 2051671 2051668 2051669 2051670 2051986 2051987 2051988 2051993 2051994 2051995 2051996 2051997 2051998 2051999 2052000 2052001 2052002 2052003 2052004 2052005 2052006 2052007 2052008 2052009 2052010 223 Specifications Nozzle 3" for FLSE100-EXPR, carbon steel Designation Nozzle CL1503Z, prepared for pipe size 12" Nozzle CL1503Z, prepared for pipe size 14" Nozzle CL1503Z, prepared for pipe size 16" Nozzle CL1503Z, prepared for pipe size 18" Nozzle CL1503Z, prepared for pipe size 20" Nozzle CL1503Z, prepared for pipe size 22" Nozzle CL1503Z, prepared for pipe size 24" Nozzle CL1503Z, prepared for pipe size 26" Nozzle CL1503Z, prepared for pipe size 28" Nozzle CL1503Z, prepared for pipe size 30" Nozzle CL1503Z, prepared for pipe size 32" Nozzle CL1503Z, prepared for pipe size 34" Nozzle CL1503Z, prepared for pipe size 36" Nozzle CL1503Z, prepared for pipe size 38" Nozzle CL1503Z, prepared for pipe size 40" Nozzle CL1503Z, prepared for pipe size 42" Nozzle CL1503Z, prepared for pipe size 44" Nozzle CL1503Z, prepared for pipe size 46" Nozzle CL1503Z, prepared for pipe size 48" Nozzle CL1503Z, prepared for pipe size 52" Nozzle CL1503Z, prepared for pipe size 56" Nozzle CL1503Z, prepared for pipe size 60" Nozzle CL1503Z, prepared for pipe size 64" Nozzle CL1503Z, prepared for pipe size 68" Nozzle CL1503Z, prepared for pipe size 72" Part No. 2057109 2057110 2059283 2059284 2057113 2057114 2059285 2057116 2057117 2057118 2057119 2057120 2057121 2057122 2057123 2057124 2057125 2057126 2057127 2057128 2057129 2057130 2057131 2057132 2057133 Nozzle installation tool Part No. 2050598 2050599 2050601 Subject to change without notice Designation Nozzle installation tool EX-S Nozzle installation tool EX Nozzle installation tool EX-PR 224 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications 6.2.8 Additional accessories for retractable sender/receiver units Designation Blind flange 2" for FLSE100-EXS and FLSE100-EXRE Blind flange ANSI CL1502Z CS, material carbon steel Blind flange 3" for FLSE100-EXPR Blind flange ANSI CL1503Z CS, material carbon steel Ball valve 2" for FLSE100-EXS and FLSE100-EXRE Ball valve ANSI CL1502Z SS, material stainless steel 1.4408 (CF08M) Ball valve 3" for FLSE100-EXPR Ball valve ANSI CL1503Z SS, material stainless steel 1.4408 (CF08M) 6.2.9 Part No. 2051991 2051990 2051963 2051966 MCUP control unit MCUP without explosion protection Fig. 157 MCUP control unit without explosion protection in compact size housing 210 125 Subject to change without notice 300 320 340 160 Designation Control unit MCUP-WNA1MN00000NRN Control unit MCUP-2NA1MN00000NRN FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Part No. 1050334 1047618 225 Specifications 57.15 MCUP control unit in 19" rack (shown with Display module option) 132.5 Fig. 158 465.9 Approx. 260 482.6 Part No. 1047704 1047705 Subject to change without notice Designation Control unit MCUP-WNF1MN00000NRN Control unit MCUP-2NF1MN00000NRN 226 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications MCUP without explosion protection and for use in zone 2 and CL I, Div 2 MCUP control unit in medium size housing 29 Fig. 159 10 330 POWER H 242 Meas 356 H = 300 (for ATEX zone 2 version 320 (for CSA CII Div 2 version Part No. 1050336 1050335 1050337 1047706 1050340 1050339 Subject to change without notice Designation Control unit MCUP-WNB3MN00000NRN Control unit MCUP-2NB3MN00000NRN Control unit MCUP-SNB3MB00000NSN Control unit MCUP-2NB3MB00000NSN Control unit MCUP-SNB3CE00000NSN Control unit MCUP-2NB3CE00000NSN FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 227 Specifications MCUP for ATEX Zone 1 Fig. 160 MCUP in Ex housing for zone 1 STAHL 227 210 445 260 210 Ø 11 360 Part No. 1048164 1047707 Subject to change without notice Designation Control unit MCUP-WND1MA00000NSN Control unit MCUP-2ND1MA00000NSN 228 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications MCUP for CSA Cl I, Div 1 Fig. 161 MCUP in Ex housing for CSA Cl I, Div 1 E A D Part No. 1069773 1069771 on request on request Subject to change without notice Designation Control Unit MCUP-2NK1CD00000NSN Control Unit MCUP-WNK1CD00000NSN Control Unit MCUP-WNL1CD00000NSN Control Unit MCUP-2NL1CD00000NSN C A ØB FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 229 Specifications 6. 3 Options for MCUP control unit 6.3.1 Inputs/outputs Designation Analog input module, 2 channels, 100 W, 0/4...22 mA, electrically isolated Analog output module, 2 channels, 500 W 0/4 ... 22 mA, electrically isolated per module Digital output module, 2 changeover contacts Module carrier (for one each AI, AO, DI or DO module) Connection cable for optional I/O modules I/O module carrier 19" (to install up to 4 AI/AO or 4 DI/DO modules) Interface module Designation Interface Modbus TCP + Impulse Interface Ethernet triplex + Impulse Interface Foundation Fieldbus Interface Impulse Interface Profibus DP + Impulse Interface Ethernet + Impulse Interface Modbus + Impulse Interface HART® BUS + Impulse 6.3.3 Part No. 2059546 2072693 on request 2048961 2048920 2055719 2048958 2050607 Interface modules for MCUP 19" version Designation Interface Modbus TCP + Impulse Interface Ethernet triplex + Impulse Interface Impulse Interface Profibus DP + Impulse Interface Ethernet + Impulse Interface Modbus + Impulse (on request) Interface HART® BUS + Impulse (on request) 6. 4 Part No. on request 2073110 2049348 2049334 2048377 2050674 2050608 Password User level 0 "Operator" 1 "Authorized client" 230 2034659 6033578 2040977 2048378 Password Without sickoptic FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice 6.3.2 Part No. 2034656 2034657 Specifications Sealing installation instruction Fig. 162 Sealing installation (designed by ”pikotek”) Subject to change without notice 6.5 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 231 232 Subject to change without notice Bolts M16 A2/A4-70 5/8 A193 gr. B8m 5/8“ A320 gr. L7m (A193 gr. B8m) Thickness of gasket No. of bolts 4 4,25 mm 4 4/8 3“/DN80 126 Nm 118 Nm 118 Nm 4,6 mm 4 2“/DN50 126 Nm 118 Nm 118 Nm Polymer gasket GYLON Fig. 163 Grooved metal gasket B9A 2“/DN50 3“/DN80 126 Nm 126 Nm 84 Nm 84 Nm 77 Nm 77 Nm Tightening torques ● Default: Grooved metal gasket B9A ● Option: Polymer gasket GYLON Specifications GYLON Sealing installation (designed by ”pikotek”), bolt torque values for grooved metal gasket B9A and polymer gasket FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications 6.6 SICK Commissioning check list Fig. 164 SICK Commissioning check list, page 1 Commissioning check list FLOWSIC100 Flare Client information Company name: Plant location: Address: Responsible Plant Manager: Phone: FAX: email: Meter information TAG number: Serial number S/R unit A: Serial number S/R unit B: Serial number MCU: Device configuration (1 path, 2 path): Device version (CrossDuct/Probe): Type key of S/R unit: Type key of MCU: Measurement Location: Add. description: Service information Subject to change without notice Date of this service: Time of this service: Technician name: Technician phone: Technician email: Date of last service: (B FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 233 Specifications Fig. 165 SICK Commissioning check list, page 2 1 Configuration sensor (QWHUDSSOLFDWLRQSDUDPHWHUV ,QVWDOODWLRQDQJOH 3DWKOHQJWK &URVVVHFWLRQDODUHD &KHFNWKH]HURSKDVHFXUVRUVVHHILJ =HURSKDVH $GMXVWPHQW E\ XVLQJ 3DUDPHWHU =HUR SKDVH VHHDOVRVHUYLFHPDQXDOIRUQHDUHULQVWUXFWLRQV &KHFN WKH SDJH 2YHUYLHZ IRU 0DOIXQFWLRQV DQG 0DLQWHQDQFH UHTXHVWV ,I WKHUH DQ\ HYHQW JRLQJ LQWR PRUH GHWDLOHGLQIRUPDWLRQRQSDJH(UURUPHVVDJHV:DUQLQJV Subject to change without notice (B 234 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications Fig. 166 SICK Commissioning check list, page 3 2 Configuration MCU 1 Enter customers data: Name, Street, City, Country 2 Enter the system configuration: Measuring point configuration Check the view for all detected hardware modules and press "Apply the detected configuration" Select the connected module and additional settings for the interface. Synchronize the runtime to customer’s local time. Configure service interface settings Protocol type, Baud rate, address. Configure reference data temperature and pressure. Configure the measuring points. Configure reference data temperature and pressure 3 Subject to change without notice Open page "Analog Input Parameter" and configure the values for pressure and temperature E_49990 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 3/9 235 Specifications Fig. 167 SICK Commissioning check list, page 4 &KDQJH WR SDJH ³0HDVXULQJ 3RLQW 3DUDPHWHU´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ubject to change without notice FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications Fig. 168 SICK Commissioning check list, page 5 &KDQJHWRSDJH,PSXOVH2XWSXWDQGHQWHU $VVLJQHGPHDVXULQJSRLQW 0HDVXULQJYDOXH ,PSXOVHIDFWRU &KDQJH WR SDJH /LPLW 6ZLWFKHV DQG FRQILJXUH IRU DOO PHDVXULQJSRLQWV $VVLJQHGPHDVXULQJSRLQW 0HDVXUHGYDOXH +\VWHUHVLVW\SH +\VWHUHVLVYDOXH 6ZLWFKLQJGLUHFWLRQ /LPLWLQJYDOXH &KHFN WKH SDJH 2YHUYLHZ IRU 0DOIXQFWLRQV DQG 0DLQWHQDQFHUHTXHVWV ,IWKHUHDUHDQ\HYHQWVVHHPRUHGHWDLOHGLQIRUPDWLRQ RQSDJH(UURUPHVVDJHV:DUQLQJV Subject to change without notice (B FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 237 Specifications Fig. 169 SICK Commissioning check list, page 6 Check Diagnostic &KHFNWKHIROORZLQJGLDJQRVWLFYDOXHVIRUSODXVLELOLW\ 92* BBBBBBBBBBBBBBBBBBBBBBBBBBBB 626 BBBBBBBBBBBBBBBBBBBBBBBBBBBB 615 BBBBBBBBBBBBBBBBBBBBBBBBBBBB $*& BBBBBBBBBBBBBBBBBBBBBBBBBBBB 3UHVVXUH BBBBBBBBBBBBBBBBBBBBBBBBBBBB 7HPSHUDWXUH BBBBBBBBBBBBBBBBBBBBBBBBBBBB 0ROZHLJKW BBBBBBBBBBBBBBBBBBBBBBBBBBBB 'HQVLW\ BBBBBBBBBBBBBBBBBBBBBBBBBBBB Check Output / Input &KHFNDQDORJRXWSXWV )RU ORRS FKHFN FKDQJH WR SDJH 6\VWHP WHVW DQG XVH WKH VLPXODWLRQ PRGH IRU $2 2XWSXWV DQG FRPSDUH ZLWK FXVWRPHUV'&66FUHHQYDOXHV $2 $2 $2 $2 $2 $2 RN RN RN RN RN RN &KHFNDQDORJLQSXWV )RU ORRS FKHFN FKDQJH WR SDJH 6\VWHP WHVW DQG XVH WKH 623$6(7VFUHHQYDOXHVDQGFRPSDUHZLWKFXVWRPHUV'&6 VFUHHQYDOXHV (B 238 $2 $2 $2 $2 $2 $2 RN RN RN RN RN RN Subject to change without notice FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications Fig. 170 SICK Commissioning check list, page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ubject to change without notice (B FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 239 Specifications Fig. 171 SICK Commissioning check list, page 8 Miscellaneous MCU &KDQJHWRSDJH/RJERRNDQGGHOHWH &KDQJH WR SDJH 0HDVXULQJ 3RLQW 3DUDPHWHU DQG UHVHW FRXQWHUV 6HOHFW RSWLRQ 7RROV'DWDUHFRUGHU RQ WKH WRROEDU DQG FRQILJXUHDGDWDUHFRUGHU DQG VHOHFW WKH ORJJLQJ JURXS 6DYHSURMHFWILOHDQGGHYLFHILOH 6DYHSURMHFW (B 240 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice 3UHVV WKH EXWWRQ ³'LDJQRVLVORJ´ Specifications Fig. 172 SICK Commissioning check list, page 9 ([SRUWGHYLFH0&8 ([SRUWGHYLFH6HQVRU ,QVWDOODWLRQDQG&RPPLVVLRQLQJZRXOGEHVXFFHVVIXOO\ILQLVKHG)ROORZLQJDGGLWLRQDOQRWHV VKRXOGEHIL[HG _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ __________________________ 7HFKQLFLDQQDPH ___________________________ 6LJQDWXUH _______________ 'DWH7LPH Subject to change without notice (B FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 241 Release 03.01.12 Date ERI Date Name Checked Norm 21 23 90 91 VOG E. Riedel 13.08.09 Modul AO 3 AO 11 12 88 89 Mass flow 3 17 18 17 18 5 20 21 20 21 6 1 1 2 2 Mal.func. E_75823 Q B RS485 A 33 34 33 34 B Model number Path 2 Sender/Receiver Unit 24 VDC Li2YcY 2x2x0,5 31 32 46 Drawing number -x1 31 32 46 47 A MCU Input 2path Q_P_T active Q 4 5 5 B B RS485 A 38 39 38 39 A Maintenance Status 4 Maint. 7 LI2YCY 5x2x0.5 8 7 8 8 Check Status 7 Check Warning Status 10 11 10 11 Warn 9 T Li2YcY 2x0,5 27 28 27 28 MCU Ex d 230V AC 1MS / 2P active RS485 4 .. 20 mA 4 .. 20 mA 2 wire Smart 2 wire Smart P Li2YcY 2x0,5 25 26 25 26 Description: Voltage: Meas. points: Transm. type: Interface: 29 30 29 30 loop powered transmitter MCUP-WNX1XA03000MSN Type key Path 1 Sender/Receiver Unit 24 VDC Li2YcY 2x2x0,5 36 37 36 37 Analog output Digital input Digital input Status 4 .. 20 mA Malfunction Mainboard Outputs 22 23 22 23 Li2YCY 5x5x0.5 4 Limit 13 14 13 14 Limit 10 A X2 SICK - 2 B 4 L1 -X13 L1 X3 LiYCY 2x1,5 N N 13 PE PE + GM = von 1 Bl. IP 55255 8125/5073-1 Ex e RS 485 A 3 RS 485 12 Example wiring diagram RS 485 Modul Puls output + 1 Volume Li2YCY 2x2x0,5 Flaremeter RS 485 gnd B 45 44 43 45 44 43 Service 11 6. 7 Connection diagrams for MCUP Ex zone 1 - configuration examples with optional modules Fig. 173 2-path configuration, 1 measuring point, supply voltage 230 V a.c. FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice MCU_Exd_230V_2P_active_RS485.0001 State EDB: B Rev. 1.06 Modul AO 2 21 23 86 87 AO 11 12 84 85 Modul AO 1 21 23 82 83 Flow AO 11 12 -x1 80 81 Li2YCY 6x2x0.5 Molecular Reserve weight SOS 2 M a i n b o a rd 230V AC PE 1 PE Modbus, Cola b configurable 242 8265/54-3111 Ex d L1 N PE Specifications Release ERI MCU_Exd_230V_2MS_active_RS485.0001 State 03.01.12 Date Date Name Checked Norm Modul AO 2 21 23 86 87 AO 11 12 84 85 Modul AO 1 21 23 82 83 Flow AO 11 12 -x1 80 81 Li2YCY 6x2x0.5 Molecular Reserve weight SOS 21 23 90 91 VOG Q B RS485 A 56 57 E. Riedel 13.08.09 6 20 21 20 21 Li2YcY 2x0,5 E_75821 Drawing number T 63 64 65 21 23 24 Li2YcY 2x0,5 4 .. 20 mA 4 .. 20 mA 2 wire Smart 2 wire Smart P 60 61 62 11 12 14 Model number Measure point 2 Sender/Receiver Unit 24 VDC Li2YcY 2x2x0,5 54 55 17 18 17 18 5 1 1 2 2 Mal.func. 4 5 5 LI2YCY 5x2x0.5 8 A B RS485 7 8 8 Warning Status 10 11 10 11 Warn 9 Limit 13 14 13 14 Limit 10 T MCU Ex d 230V 2 MS active RS485 Measure point 1 X2 - 2 B 4 L1 -X13 L1 X3 LiYCY 2x1,5 N N 13 PE PE + GM = von 1 Bl. IP 55255 8125/5073-1 Ex e RS 485 A 3 RS 485 12 Example wiring diagram RS 485 Modul Puls output + 1 Volume Li2YCY 2x2x0,5 11 Flaremeter SICK Li2YcY 2x0,5 27 28 27 28 RS 485 A 45 44 43 gnd B 4 .. 20 mA 4 .. 20 mA 2 wire Smart 2 wire Smart P 25 26 29 30 Li2YcY 2x0,5 25 26 29 30 Service 45 44 43 loop powered transmitter AI 1 AI 2 Check Status 7 Check Description: Voltage: Meas. points: Transm. type: Interface: Sender/Receiver Unit 24 VDC Q 38 39 36 37 Li2YcY 2x2x0,5 38 39 B 36 37 A MCU Input 2MS Q_P_T active Maintenance Status 4 Maint. 7 MCUP-WNX2XA13000MSN Type key 46 47 Analog output Digital input Digital input Status 4 .. 20 mA Malfunction Mainboard Outputs 22 23 22 23 Li2YCY 5x5x0.5 4 loop powered transmitter AI 3 AI 4 Modul AO 3 AO 11 12 88 89 Mass flow AI Modul 1 L1 N PE 3 PE 2 PE 230V AC M a i n b o a rd 1 PE FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG PE Modbus, Cola b configurable Fig. 174 8265/54-3111 Ex d Subject to change without notice Specifications 1-path configuration, 2 measuring points, supply voltage 230 V a.c. 243 80 81 A B RS485 Release Li2YcY 2x0,5 03.01.12 Date ERI T 69 70 71 21 23 24 Li2YcY 2x0,5 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG E. Riedel 13.08.09 Subject to change without notice Date Name Checked Norm 17 18 17 18 5 20 21 20 21 6 1 1 2 2 Mal.func. Q B RS485 A 56 57 E_75822 Li2YcY 2x0,5 Model number T 63 64 65 4 5 Li2YcY 2x0,5 Maintenance MCUP-WNX3XA23000MSN Type key 5 Status 4 Maint. 7 4 .. 20 mA 4 .. 20 mA 2 wire Smart 2 wire Smart P 60 61 62 21 23 24 Measure point 2 Sender/Receiver Unit 24 VDC Li2YcY 2x2x0,5 54 55 11 12 14 loop powered transmitter AI 3 AI 4 Analog output Digital input Digital input Status 4 .. 20 mA Malfunction Mainboard Outputs 22 23 22 23 Li2YCY 5x5x0.5 4 Drawing number 4 .. 20 mA 4 .. 20 mA 2 wire Smart 2 wire Smart P 66 67 68 11 12 14 Measure point 3 MCU_Exd_230V_3MS_active_RS485.0001 State Q 52 53 Sender/Receiver Unit 24 VDC Li2YcY 2x2x0,5 50 51 21 23 90 91 VOG Modul AO 3 AO 11 12 88 89 Mass flow loop powered transmitter AI 5 AI 6 Modul AO 2 21 23 Modul AO 1 11 12 86 87 AO 21 23 84 85 AO 11 12 82 83 AI Modul 2 -x1 Flow PE Li2YCY 6x2x0.5 Molecular Reserve weight SOS PE AI Modul 1 3 PE 2 8 7 8 8 Warning Status 10 11 10 11 Warn 9 A B RS485 MCU Ex d 230V 3 MS active RS485 Sender/Receiver Unit 24 VDC Q 38 39 36 37 Li2YcY 2x2x0,5 38 39 B 36 37 A MCU Input 3MS Q_P_T active Check Status 7 Check Description: Voltage: Meas. points: Transm. type: Interface: 46 47 LI2YCY 5x2x0.5 M a i n b o a rd 230V AC RS 485 gnd B A 45 44 43 45 44 43 Service X2 RS 485 Modul T Li2YcY 2x0,5 27 28 27 28 SICK Flaremeter Measure point 1 B 4 L1 -X13 L1 X3 LiYCY 2x1,5 N N 13 PE PE + GM = von 1 Bl. IP 55255 8125/5073-1 Ex e RS 485 A 3 RS 485 12 Example wiring diagram 4 .. 20 mA 4 .. 20 mA 2 wire Smart 2 wire Smart P 25 26 29 30 Li2YcY 2x0,5 25 26 29 30 - 2 Puls output + 1 Volume Li2YCY 2x2x0,5 11 loop powered transmitter AI 1 AI 2 Limit 13 14 13 14 Limit 10 PE 1 PE Modbus, Cola b configurable 244 PE Fig. 175 8265/54-3111 Ex d L1 N PE Specifications 1-path configuration, 3 measuring points, supply voltage 230 V a.c. Specifications Wiring diagrams for USA and Canada 6.8.1 FLSE100-EXS/FLSE100-EXPR Fig. 176 Type key FLSE100-EXS/FLSE100-EXPR Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Subject to change without notice A4_Formblatt_ME10.CDR 6.8 Tag Name gez. 2008-08-05 MKO gepr. 2009-08-18 Kochan Maßstab: B 2010-08-31 A 2009-12-04 Ind. Änderung Tag MKO Kochan MKO Kochan Name Gepr. SICK Engineering GmbH Bergener Ring 27 01458 Ottendorf-Okrilla FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Werkstoff Norm-Typ/DIN Manufacturer drawing FLSE100-EXS/-EXPR E_41943 Ursprung: Page 1 of 6 Verteildatum: Ersatz für: Ersetzt durch: 245 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Coaxial Cable Coaxial Cable Coaxial Cable Coaxial Cable Coaxial Cable AWG 12 Data Interface (RS485) Terminals A, B +/- 5 V, max. 500mA Power supply Terminals +24V, GND 15...28 V dc, 500mA max. Subject to change without notice Temperature range and pressure range see Marking plate Temperature Sensor [Exia], mfg. by SICK only Ultrasonic Transducers [Exia], mfg. by SICK only Entity Parameters Voc = 8.6 V, Isc = 5 mA Ca < 5 μF, La < 1 mH Ci, Li negligible Temperature Sensor [Exia], mfg. by SICK only AWG 20 up to 16 AWG 20 up to 16 MASTER Ind. Änderung Tag 2009-12-04 Name MKO Gepr. Kochan Conduit size 1/2" NPT AWG 20 up to 16 AWG 16 AWG 16 A MASTER AWG 20 up to 16 AWG 16 AWG 16 GND Entity Parameters Voc = 38.9 V, Isc = 59 mA Ca < 30 nF, La < 0.03 mH Ci negligible, Li < 6.7 mH AWG 12 A GND B +24V Coaxial Cable GND A Ultrasonic Transducers [Exia], mfg. by SICK only TYPE 4, IP 65 A +24V SLAVE -50°C < Tamb <70°C, ambient pressure A +24V B Zone separating wall, e.g. pipeline or duct GND B +24V B Bergener Ring 27 01458 Ottendorf-Okrilla SICK Engineering GmbH Maßstab: 2009-08-18 Kochan gepr. Name 2008-08-05 MKO gez. Tag Norm-Typ/DIN Ersetzt durch: Ersatz für: Ursprung: E_41943 Verteildatum: 2 of 6 Page Manufacturer drawing FLSE100-EXS/-EXPR Werkstoff 7. Maximum non hazardous area voltage not to exeed 125V 6. [Exia] WARNING: Substitution of components may impair Intrinsic Safety 5. WARNING: Explosion Hazard - Substitution may impair suitabilty for Class I Division 2 4. WARNING: Explosion Hazard - Do not connect or disconnect this equipment unless power has been switched off or the area is known to be nonhazardous. 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) and ANSI/ISA RP12.6 1. This equipment is suitable for installation in Class I, Division 2, Groups A, B, C and D hazardous locations or nonhazardous locations only. Division2 / Zone 2 Installation 4. [Exia] WARNING: Substitution of components may impair Intrinsic Safety 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) and ANSI/ISA RP12.6 1. Maximum non hazardous area voltage not to exeed 125V Division1 / Zone 0 / Zone 1 Installation A4_Formblatt_ME10.CDR Fig. 177 SLAVE 246 Class I, Division 1, Groups B, C and D, Temp.Code T4, Class I, Division 2, Groups A, B, C and D, Temp.Code T4 Class I, Zone 1: Ex/AEx d[ia] IIB + H2, Temp.Code T4, Class I, Zone 2: Ex/AEx nA[ia] IIC, Temp.Code T4 Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Specifications Wiring diagram for FLSE100-EXS/FLSE100-EXPR FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Temperature range and pressure range see Marking plate Temperature Sensor [Exia], mfg. by SICK only Ultrasonic Transducers [Exia], mfg. by SICK only Entity Parameters Voc = 8.6 V, Isc = 5 mA Ca < 5 μF, La < 1 mH Ci, Li negligible Temperature Sensor [Exia], mfg. by SICK only AWG 12 Data Interface (RS485) Terminals A, B +/- 5 V, max. 500mA Power supply Terminals +24V, GND 15...28 V dc, 500mA max. Coaxial Cable Coaxial Cable Coaxial Cable Coaxial Cable Coaxial Cable MASTER MASTER Ind. Änderung Tag 2009-12-04 Name MKO Gepr. Kochan Conduit size 1/2" NPT AWG 20 up to 16 AWG 16 AWG 16 AWG 20 up to 16 AWG 20 up to 16 AWG 16 AWG 16 A TYPE 4, IP 65 AWG 20 up to 16 GND Entity Parameters Voc = 51.2 V, Isc = 77 mA Ca < 18 nF, La < 0.03 mH Ci negligible, Li < 6.7 mH A GND B +24V AWG 12 GND A Coaxial Cable A +24V SLAVE Ultrasonic Transducers [Exia], mfg. by SICK only A +24V B Zone separating wall, e.g. pipeline or duct GND B +24V B Bergener Ring 27 01458 Ottendorf-Okrilla SICK Engineering GmbH Maßstab: 2009-08-18 Kochan gepr. Name 2008-08-05 MKO gez. Tag Norm-Typ/DIN Ersetzt durch: Ersatz für: Ursprung: E_41943 Verteildatum: 3 of 6 Page Manufacturer drawing FLSE100-EXS-C/-EXPR-C Werkstoff 7. Maximum non hazardous area voltage not to exeed 125V 6. [Exia] WARNING: Substitution of components may impair Intrinsic Safety 5. WARNING: Explosion Hazard - Substitution may impair suitabilty for Class I Division 2 4. WARNING: Explosion Hazard - Do not connect or disconnect this equipment unless power has been switched off or the area is known to be nonhazardous. 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) and ANSI/ISA RP12.6 1. This equipment is suitable for installation in Class I, Division 2, Groups C and D hazardous locations or nonhazardous locations only. Division2 / Zone 2 Installation 4. [Exia] WARNING: Substitution of components may impair Intrinsic Safety 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) and ANSI/ISA RP12.6 1. Maximum non hazardous area voltage not to exeed 125V Division1 / Zone 0 / Zone 1 Installation A4_Formblatt_ME10.CDR Fig. 178 SLAVE -50°C < Tamb <70°C, ambient pressure Class I, Division 1, Groups C and D, Temp.Code T4, Class I, Division 2, Groups C and D, Temp.Code T4 Class I, Zone 1: Ex/AEx d[ia] IIB, Temp.Code T4, Class I, Zone 2: Ex/AEx nA[ia] IIB, Temp.Code T4 Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Subject to change without notice Specifications Wiring diagram for FLSE100-EXS/FLSE100-EXPR 247 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Coaxial Cable Coaxial Cable Coaxial Cable Coaxial Cable Coaxial Cable AWG 12 Data Interface (RS485) Terminals A, B +/- 5 V, max. 500mA Power supply Terminals +24V, GND 15...28 V dc, 500mA max. Subject to change without notice Temperature range and pressure range see Marking plate Temperature Sensor [Exia], mfg. by SICK only Ultrasonic Transducers [Exia], mfg. by SICK only Entity Parameters Voc = 8.6 V, Isc = 5 mA Ca < 5 μF, La < 1 mH Ci, Li negligible Temperature Sensor [Exia], mfg. by SICK only AWG 20 up to 16 AWG 20 up to 16 MASTER Ind. Änderung Tag 2009-12-04 Name MKO Gepr. Kochan Conduit size 1/2" NPT AWG 20 up to 16 AWG 16 AWG 16 A MASTER AWG 20 up to 16 AWG 16 AWG 16 GND Entity Parameters Voc = 60.8 V, Isc = 92 mA Ca < 30 nF, La < 0.03 mH Ci negligible, Li < 6.7 mH AWG 12 A GND B +24V Coaxial Cable GND A Ultrasonic Transducers [Exia], mfg. by SICK only TYPE 4, IP 65 A +24V SLAVE -50°C < Tamb <70°C, ambient pressure A +24V B Zone separating wall, e.g. pipeline or duct GND B +24V B Bergener Ring 27 01458 Ottendorf-Okrilla SICK Engineering GmbH Maßstab: 2009-08-18 Kochan gepr. Name 2008-08-05 MKO gez. Tag Norm-Typ/DIN Ersetzt durch: Ersatz für: Ursprung: E_41943 Verteildatum: 4 of 6 Page Manufacturer drawing FLSE100-EXS-D/-EXPR-D Werkstoff 7. Maximum non hazardous area voltage not to exeed 125V 6. [Exia] WARNING: Substitution of components may impair Intrinsic Safety 5. WARNING: Explosion Hazard - Substitution may impair suitabilty for Class I Division 2 4. WARNING: Explosion Hazard - Do not connect or disconnect this equipment unless power has been switched off or the area is known to be nonhazardous. 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) and ANSI/ISA RP12.6 1. This equipment is suitable for installation in Class I, Division 2, Group D hazardous locations or nonhazardous locations only. Division2 / Zone 2 Installation 4. [Exia] WARNING: Substitution of components may impair Intrinsic Safety 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) and ANSI/ISA RP12.6 1. Maximum non hazardous area voltage not to exeed 125V Division1 / Zone 0 / Zone 1 Installation A4_Formblatt_ME10.CDR Fig. 179 SLAVE 248 Class I, Division 1, Group D, Temp.Code T4, Class I, Division 2, Group D, Temp.Code T4 Class I, Zone 1: Ex/AEx d[ia] IIA, Temp.Code T4, Class I, Zone 2: Ex/AEx nA[ia] IIA, Temp.Code T4 Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Specifications Wiring diagram for FLSE100-EXS/FLSE100-EXPR FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Temperature range and pressure range see Marking plate Temperature Sensor [Exia], mfg. by SICK only Ultrasonic Transducers [Exia], mfg. by SICK only Entity Parameters Voc = 8.6 V, Isc = 5 mA Ca < 5 μF, La < 1 mH Ci, Li negligible Temperature Sensor [Exia], mfg. by SICK only AWG 12 Data Interface (RS485) Terminals A, B +/- 5 V, max. 500mA Power supply Terminals +24V, GND 15...28 V dc, 500mA max. Coaxial Cable Coaxial Cable Coaxial Cable Coaxial Cable Coaxial Cable MASTER MASTER Ind. Änderung Tag 2009-12-04 Name MKO Gepr. Kochan Conduit size 1/2" NPT AWG 20 up to 16 AWG 16 AWG 16 AWG 20 up to 16 AWG 20 up to 16 AWG 16 A TYPE 4, IP 65 AWG 20 up to 16 AWG 16 GND Entity Parameters Voc = 38.9 V, Isc = 59 mA Ca < 3.4 nF, La < 0.03 mH Ci negligible, Li < 6.7 mH A GND B +24V AWG 12 GND A Coaxial Cable A +24V SLAVE Ultrasonic Transducers [Exia], mfg. by SICK only A +24V B Zone separating wall, e.g. pipeline or duct GND B +24V B Bergener Ring 27 01458 Ottendorf-Okrilla SICK Engineering GmbH Maßstab: 2009-08-18 Kochan gepr. Name 2008-08-05 MKO gez. Tag Norm-Typ/DIN Ersetzt durch: Ersatz für: Ursprung: E_41943 Verteildatum: 5 of 6 Page Manufacturer drawing FLSE100-EXS-6/-EXPR-6 Werkstoff 7. Maximum non hazardous area voltage not to exeed 125V 6. [Exia] WARNING: Substitution of components may impair Intrinsic Safety 5. WARNING: Explosion Hazard - Substitution may impair suitabilty for Class I Division 2 4. WARNING: Explosion Hazard - Do not connect or disconnect this equipment unless power has been switched off or the area is known to be nonhazardous. 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) and ANSI/ISA RP12.6 1. This equipment is suitable for installation in Class I, Division 2, Groups A, B, C and D hazardous locations or nonhazardous locations only. Division2 / Zone 2 Installation 4. [Exia] WARNING: Substitution of components may impair Intrinsic Safety 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) and ANSI/ISA RP12.6 1. Maximum non hazardous area voltage not to exeed 125V Division1 / Zone 0 / Zone 1 Installation A4_Formblatt_ME10.CDR Fig. 180 SLAVE -50°C < Tamb <55°C, ambient pressure Class I, Division 1, Groups B, C and D, Temp.Code T6, Class I, Division 2, Groups A, B, C and D, Temp.Code T6 Class I, Zone 1: Ex/AEx d[ia] IIB + H2, Temp.Code T6, Class I, Zone 2: Ex/AEx nA[ia] IIC, Temp.Code T6 Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Subject to change without notice Specifications Wiring diagram for FLSE100-EXS/FLSE100-EXPR 249 250 +++ +++ +++ +++ + +++ +++ + +++ +++ O2 water steam up to 100°C water steam up to 280°C CH4 / natural gas sour gas CO2 flare gas Cl2 H2 NH4 +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice - +++ ++ +++ +++ + +++ - - ++ ++ +++ - not suitable +++ +++ - +++ + +++ - - +++ + - +++ Ind. Änderung A B Gepr. Kochan Name MKO 2009-12-04 Tag Kochan MKO HS – hastelloy +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ -15°C up to +280°C 2010-05-26 Ti - titanum grade2 / grade5 + conditional good +++ + - +++ +++ +++ +++ +++ +++ + - +++ *) For information only. Suitability have to be checked by the user **) Rated gas temperature and MWP see marking plate ***) For retractable ultrasonic transducer only. Indicated in the type code, see marking plate. Leacking O-rings have to be changed by the SICK service only. SS - stainless steel group 4 ; ++ good - HF +++ very good +++ Bergener Ring 27 01458 Ottendorf-Okrilla SICK Engineering GmbH Maßstab: 2009-08-18 Kochan Name gepr. Tag 2008-08-05 MKO gez. -50°C up to +100° -40°C up to +180°C FFKM Kalrez TM EPDM Vistalon TM FKM Viton TM HS SS Ti Sealing material in the retraction flange ***) Ultrasonic transducer material Norm-Typ/DIN Ersetzt durch: Ersatz für: Ursprung: E_41943 Verteildatum: 6 of 6 Page Manufacturer drawing FLSE100-EXS/-EXPR Werkstoff A4_Formblatt_ME10.CDR Fig. 181 air / like air Medium**) Suitability of Materials *) Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Specifications Materials Specifications FLSE100-EX/FLSE100-EXRE Fig. 182 Type key FLSE100-EX/FLSE100-EXRE Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Subject to change without notice A4_Formblatt_ME10.CDR 6.8.2 Tag Name gez. 2008-08-05 MKO gepr. 2009-08-18 Kochan Maßstab: B 2010-08-31 A 2009-12-04 Ind. Änderung Tag MKO Kochan MKO Kochan Name Gepr. SICK Engineering GmbH Bergener Ring 27 01458 Ottendorf-Okrilla FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Werkstoff Norm-Typ/DIN Manufacturer drawing FLSE100-EX/-EXRE E_41944 Ursprung: Page 1 of 5 Verteildatum: Ersatz für: Ersetzt durch: 251 Subject to change without notice Ultrasonic Transducer FLANGE AWG 12 MASTER Ind. Änderung A B Gepr. Kochan Name MKO 2009-12-04 Tag Kochan MKO 2010-08-31 Data Interface (RS485) Terminals A, B +/- 5 V, 500mA max. Power supply Terminals +24V, GND 15...28 V dc, 500mA max. Conduit size 1/2" NPT AWG 20 up to 16 AWG 16 AWG 16 AWG 20 up to 16 TYPE 6, IP 65/67 SINGLE SEAL A GND B A AWG 12 GND +24V -50°C < Tamb <70°C, ambient pressure +24V B Bergener Ring 27 01458 Ottendorf-Okrilla SICK Engineering GmbH Maßstab: 2009-08-18 Kochan gepr. Name 2008-08-05 MKO gez. Tag Norm-Typ/DIN Ersetzt durch: Ersatz für: Ursprung: E_41944 Verteildatum: 2 of 5 Page Manufacturer Drawing FLSE100-EX/-RE Werkstoff 5. WARNING: Explosion Hazard - Substitution may impair suitabilty for Class I Division 2 4. WARNING: Explosion Hazard - Do not connect or disconnect this equipmentn unless power has been switched off or the area is known to be nonhazardous 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) 1. This equipment is suitable for installation in Class I, Division 2, Grouos A, B, C and D hazardous locations or nonhazardous locations only. Division2 / Zone 2 Installation 2. In Canada install in accordance with the CEC part 1 1. In the US install in accordance with the NEC (ANSI/NFPA 70) Division1 / Zone 1 Installation A4_Formblatt_ME10.CDR Fig. 183 SLAVE 252 Class I, Division 1, Groups B, C and D, Temp.Code T4, Class I, Division 2, Groups A, B, C and D, Temp.Code T4 Class I, Zone 1: Ex/AEx d IIB + H2, Temp.Code T4, Class I, Zone 2: Ex/AEx nA IIC, Temp.Code T4 Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Specifications Wiring diagram for FLSE100-EX/FLSE100-EXRE FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG AWG 12 AWG 20 up to 16 AWG 16 MASTER GND AWG 16 AWG 20 up to 16 TYPE 6, IP 65/67 SINGLE SEAL A B FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Ind. Änderung A B Gepr. Kochan Name MKO 2009-12-04 Tag Kochan MKO 2010-08-31 Data Interface (RS485) Terminals A, B +/- 5 V, 500mA max. Power supply Terminals +24V, GND 15...28 V dc, 500mA max. Conduit size 1/2" NPT AWG 12 A Ultrasonic Transducer FLANGE -50°C < Tamb <70°C, ambient pressure Class I, Division 1, Groups B, C and D, Temp.Code T4, Class I, Division 2, Groups A, B, C and D, Temp.Code T4 Class I, Zone 1: Ex/AEx d IIB + H2, Temp.Code T4, Class I, Zone 2: Ex/AEx nA IIC, Temp.Code T4 GND +24V Temperature range and pressure range see Marking plate Zone separating wall e.g. pipeline or duct Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. +24V B Bergener Ring 27 01458 Ottendorf-Okrilla SICK Engineering GmbH Maßstab: 2009-08-18 Kochan gepr. Name 2008-08-05 MKO gez. Tag Norm-Typ/DIN Ersetzt durch: Ersatz für: Ursprung: E_41944 Verteildatum: 3 of 5 Page Manufacturer Drawing FLSE100-EX/-RE Werkstoff 5. WARNING: Explosion Hazard - Substitution may impair suitabilty for Class I Division 2 4. WARNING: Explosion Hazard - Do not connect or disconnect this equipmentn unless power has been switched off or the area is known to be nonhazardous 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) 1. This equipment is suitable for installation in Class I, Division 2, Grouos A, B, C and D hazardous locations or nonhazardous locations only. Division2 / Zone 2 Installation 2. In Canada install in accordance with the CEC part 1 1. In the US install in accordance with the NEC (ANSI/NFPA 70) Division1 / Zone 1 Installation A4_Formblatt_ME10.CDR Fig. 184 SLAVE Subject to change without notice Specifications Wiring diagram for FLSE100-EX/FLSE100-EXRE 253 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Subject to change without notice Ultrasonic Transducer AWG 12 MASTER Ind. Änderung A B Gepr. Kochan Name MKO 2009-12-04 Tag Kochan MKO 2010-08-31 Data Interface (RS485) Terminals A, B +/- 5 V, 500mA max. Power supply Terminals +24V, GND 15...28 V dc, 500mA max. Conduit size 1/2" NPT AWG 20 up to 16 AWG 16 AWG 16 AWG 20 up to 16 TYPE 6, IP 65/67 SINGLE SEAL GND B A AWG 12 GND +24V Temperature range and pressure range see Marking plate FLANGE -50°C < Tamb <55°C, ambient pressure Class I, Division 1, Groups B, C and D, Temp.Code T6, Class I, Division 2, Groups A, B, C and D, Temp.Code T6 Class I, Zone 1: Ex/AEx d IIB + H2, Temp.Code T6, Class I, Zone 2: Ex/AEx nA IIC, Temp.Code T6 A SLAVE 254 +24V B Bergener Ring 27 01458 Ottendorf-Okrilla SICK Engineering GmbH Maßstab: 2009-08-18 Kochan gepr. Name 2008-08-05 MKO gez. Tag Norm-Typ/DIN Ersetzt durch: Ersatz für: Ursprung: E_41944 Verteildatum: 4 of 5 Page Manufacturer Drawing FLSE100-EX-6/-RE-6 Werkstoff 5. WARNING: Explosion Hazard - Substitution may impair suitabilty for Class I Division 2 4. WARNING: Explosion Hazard - Do not connect or disconnect this equipmentn unless power has been switched off or the area is known to be nonhazardous 3. In Canada install in accordance with the CEC part 1 2. In the US install in accordance with the NEC (ANSI/NFPA 70) 1. This equipment is suitable for installation in Class I, Division 2, Grouos A, B, C and D hazardous locations or nonhazardous locations only. Division2 / Zone 2 Installation 2. In Canada install in accordance with the CEC part 1 1. In the US install in accordance with the NEC (ANSI/NFPA 70) Division1 / Zone 1 Installation A4_Formblatt_ME10.CDR Fig. 185 Zone separating wall e.g. pipeline or duct Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Specifications Wiring diagram for FLSE100-EX/FLSE100-EXRE FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG +++ +++ H2 NH4 +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ HS - +++ ++ +++ +++ + +++ - - ++ ++ Ind. Änderung A B Gepr. Kochan Name MKO 2009-12-04 Tag Kochan MKO HS – hastelloy +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ Bergener Ring 27 01458 Ottendorf-Okrilla Maßstab: 2009-08-18 Kochan Name gepr. Tag 2008-08-05 MKO gez. SICK Engineering GmbH -15°C up to +280°C FFKM Kalrez TM 2010-05-26 Ti - titanum grade2 / grade5 - not suitable +++ +++ - +++ + +++ - - +++ + - +++ -50°C up to +100° -40°C up to +180°C +++ EPDM Vistalon TM FKM Viton TM + conditional good +++ + - +++ +++ +++ +++ +++ +++ + - +++ Ti Sealing material in the retraction flange ***) *) For information only. Suitability have to be checked by the user **) Rated gas temperature and MWP see marking plate ***) For retractable ultrasonic transducer only. Indicated in the type code, see marking plate. Leacking O-rings have to be changed by the SICK service only. SS - stainless steel group 4 ; ++ good + Cl2 +++ very good +++ flare gas +++ CH4 / natural gas + +++ water steam up to 280°C +++ +++ water steam up to 100°C CO2 +++ O2 sour gas +++ - HF SS Ultrasonic transducer material Norm-Typ/DIN Ersetzt durch: Ersatz für: Ursprung: E_41944 Verteildatum: 5 of 5 Page Manufacturer drawing FLSE100-EX/-EXRE Werkstoff A4_Formblatt_ME10.CDR Fig. 186 air / like air Medium**) Suitability of Materials *) Vervielfaeltigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes unzulaessig, soweit nicht ausdruecklich zugestanden. Zuwiderhandlungen sind strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte fuer den Fall der Patenterteilung oder GM-Eintragung vorbehalten. Subject to change without notice Specifications Materials 255 Specifications 6.8.3 Connection of external pressure and temperature transmitters Fig. 187 FLOWSIC100 Flare - loop powered pressure and temperature transmitters MCUP Terminals Subject to change without notice Terminals 256 FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG Specifications Fig. 188 FLOWSIC100 Flare - external powered pressure and temperature transmitters MCUP Subject to change without notice Terminals FLOWSIC100 Flare · Operating Instructions · 8013344 V 2.2 · © SICK AG 257 8013344/2014-06/V2.2/ISubject to change without notice Australia Phone +61 3 9457 0600 1800 334 802 – tollfree E-Mail [email protected] Belgium/Luxembourg Phone +32 (0)2 466 55 66 E-Mail [email protected] Brasil Phone +55 11 3215-4900 E-Mail [email protected] Canada Phone +1 905 771 14 44 E-Mail [email protected] Česká Republika Phone +420 2 57 91 18 50 E-Mail [email protected] China Phone +86 4000 121 000 E-Mail [email protected] Phone +852-2153 6300 E-Mail [email protected] Danmark Phone +45 45 82 64 00 E-Mail [email protected] Deutschland Phone +49 211 5301-301 E-Mail [email protected] España Phone +34 93 480 31 00 E-Mail [email protected] France Phone +33 1 64 62 35 00 E-Mail [email protected] Great Britain Phone +44 (0)1727 831121 E-Mail [email protected] India Phone +91–22–4033 8333 E-Mail [email protected] Israel Phone +972-4-6881000 E-Mail [email protected] Italia Phone +39 02 27 43 41 E-Mail [email protected] Japan Phone +81 (0)3 3358 1341 E-Mail [email protected] Magyarország Phone +36 1 371 2680 E-Mail [email protected] Nederland Phone +31 (0)30 229 25 44 E-Mail [email protected] SICK AG | Waldkirch | Germany | www.sick.com Norge Phone +47 67 81 50 00 E-Mail [email protected] Österreich Phone +43 (0)22 36 62 28 8-0 E-Mail [email protected] Polska Phone +48 22 837 40 50 E-Mail [email protected] România Phone +40 356 171 120 E-Mail [email protected] Russia Phone +7-495-775-05-30 E-Mail [email protected] Schweiz Phone +41 41 619 29 39 E-Mail [email protected] Singapore Phone +65 6744 3732 E-Mail [email protected] Slovenija Phone +386 (0)1-47 69 990 E-Mail [email protected] South Africa Phone +27 11 472 3733 E-Mail [email protected] South Korea Phone +82 2 786 6321/4 E-Mail [email protected] Suomi Phone +358-9-25 15 800 E-Mail [email protected] Sverige Phone +46 10 110 10 00 E-Mail [email protected] Taiwan Phone +886 2 2375-6288 E-Mail [email protected] Türkiye Phone +90 (216) 528 50 00 E-Mail [email protected] United Arab Emirates Phone +971 (0) 4 88 65 878 E-Mail [email protected] USA/México Phone +1(952) 941-6780 1 (800) 325-7425 – tollfree E-Mail [email protected] More representatives and agencies at www.sick.com